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Komatsu 830E-AC Dump Truck Shop Manual A30001-A30035 – PDF DOWNLOAD
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Komatsu 830E-AC Dump Truck Shop Manual
SERIAL NUMBERS A30001 – A30035
Book Code: CEBM016204
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Description
Komatsu 830E-AC Dump Truck Shop Manual
FILE DETAILS:
Komatsu 830E-AC Dump Truck Shop Manual
Language : English
Pages : 1134
Downloadable : Yes
File Type : PDF
Size: 30.6
Book Code: CEBM016204
DESCRIPTION:
Komatsu 830E-AC Dump Truck Shop 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.
TABLE OF CONTENTS:
Komatsu 830E-AC Dump Truck Shop Manual
COVER .............................................................................................. 1 FOREWORD ........................................................................................... 5 TABLE OF CONTENTS .................................................................................. 7 SECTION A GENERAL INFORMATION ...................................................................... 9 MAJOR COMPONENT DESCRIPTION..................................................................... 11 SPECIFICATIONS.............................................................................. 13 Truck And Engine............................................................................ 11 AC Induction Traction Motorized Wheels...................................................... 11 Suspension.................................................................................. 11 Operator's Cab.............................................................................. 11 Power Steering.............................................................................. 11 Dynamic Retarding........................................................................... 11 Brake System................................................................................ 11 GENERAL SAFETY AND OPERATING INSTRUCTIONS....................................................... 15 GENERAL SAFETY.............................................................................. 19 Safety Rules............................................................................ 19 Truck Safety Features................................................................... 19 Clothing And Personal Items............................................................. 19 Unauthorized Modification............................................................... 19 Leaving The Operator’s Seat............................................................. 19 Mounting And Dismounting................................................................ 20 Fire Extinguishers And First Aid Kits................................................... 20 Precautions For High Temperature Fluids................................................. 20 Asbestos Dust Hazard Prevention......................................................... 20 Fire Prevention For Fuel And Oil........................................................ 21 ROPS Precautions........................................................................ 21 Preventing Injury From Work Equipment................................................... 21 Precautions For Optional Attachments.................................................... 21 Precautions When Starting The Machine................................................... 21 PRECAUTIONS FOR TRUCK OPERATION............................................................. 22 Safety Is Thinking Ahead................................................................ 22 Safety At The Worksite.................................................................. 22 Fire Prevention......................................................................... 22 Preparing For Operation................................................................. 22 Ventilation For Enclosed Areas.......................................................... 22 Mirrors, Windows, And Lights............................................................ 23 In The Operator’s Cab - Before Starting The Engine...................................... 23 Seat Belts.............................................................................. 23 OPERATING THE MACHINE....................................................................... 23 Starting The Engine..................................................................... 23 Truck Operation - General............................................................... 23 Traveling In The Truck.................................................................. 24 Precautions When Traveling In Reverse................................................... 24 Traveling On Slopes..................................................................... 24 Ensuring Good Visibility................................................................ 25 Operating On Snow....................................................................... 25 Avoid Damage To The Dump Body........................................................... 25 Driving Near High Voltage Cables........................................................ 25 When Loading The Truck.................................................................. 25 When Dumping............................................................................ 25 Working On Loose Ground................................................................. 26 Parking The Machine..................................................................... 26 TOWING...................................................................................... 26 WORKING NEAR BATTERIES...................................................................... 27 Jump Starting With Booster Cables....................................................... 28 Jump Starting With Receptacles.......................................................... 28 PRECAUTIONS FOR MAINTENANCE................................................................. 29 BEFORE PERFORMING MAINTENANCE........................................................... 29 Stopping The Engine Before Service.................................................. 29 Warning Tag......................................................................... 29 Proper Tools........................................................................ 29 Securing The Dump Body.............................................................. 29 DURING MAINTENANCE...................................................................... 31 Personnel........................................................................... 31 Attachments......................................................................... 31 Working Under The Machine........................................................... 31 Keeping The Machine Clean........................................................... 31 Rules To Follow When Adding Fuel Or Oil............................................. 31 Radiator Coolant Level.............................................................. 31 Use Of Lighting..................................................................... 31 Precautions With The Battery........................................................ 32 Handling High Pressure Hoses........................................................ 32 Precautions With High Pressure Oil.................................................. 32 Maintenance Near High Temperatures And High Pressures............................... 32 Rotating Fan And Belts.............................................................. 32 Waste Materials..................................................................... 32 TIRES....................................................................................... 33 Handling Tires.......................................................................... 33 Tire Maintenance........................................................................ 34 Storing Tires After Removal............................................................. 34 ADDITIONAL JOB SITE RULES................................................................... 35 WHEN REPAIRS ARE NECESSARY.................................................................. 36 Use of Tie-Off Anchor During Maintenance................................................ 36 SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK.......................................... 37 Preliminary Procedures before Welding or Performing Maintenance......................... 37 Engine Shutdown Procedure before Welding or Performing Maintenance...................... 37 CAPACITOR DISCHARGE SYSTEM.................................................................. 39 Necessary Tools......................................................................... 39 Warnings And Cautions................................................................... 40 MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE............................................ 41 Preparation......................................................................... 41 CAPACITOR CHARGE LIGHTS................................................................. 43 FAILURE OF DISCHARGE SYSTEM............................................................. 44 Measuring Dc Voltage On Capacitors.................................................. 44 MANUAL DISCHARGE OF CAPACITORS.......................................................... 45 SHORT ISOLATED CAPACITOR TERMINALS...................................................... 47 OPERATING INSTRUCTIONS...................................................................... 49 PREPARING FOR OPERATION................................................................. 49 Safety Is Thinking Ahead............................................................ 49 WALK AROUND INSPECTION.................................................................. 49 ENGINE START-UP SAFETY PRACTICES........................................................ 53 AFTER ENGINE HAS STARTED................................................................ 54 EMERGENCY STEERING SYSTEM............................................................... 55 Operation........................................................................... 55 Pre-Operation Testing............................................................... 55 Additional Guidelines............................................................... 56 MACHINE OPERATION SAFETY PRECAUTIONS.................................................... 56 MACHINE OPERATION ON THE HAUL ROAD...................................................... 57 STARTING ON A GRADE WITH A LOADED TRUCK................................................. 58 PASSING................................................................................. 58 LOADING................................................................................. 58 DUMPING................................................................................. 58 Raising The Dump Body............................................................... 58 Lowering The Dump Body.............................................................. 59 SUDDEN LOSS OF ENGINE POWER............................................................. 61 FUEL DEPLETION.......................................................................... 61 SAFE PARKING PROCEDURES................................................................. 62 NORMAL ENGINE SHUTDOWN PROCEDURE........................................................ 62 DELAYED ENGINE SHUTDOWN PROCEDURE....................................................... 63 DISABLED TRUCK DUMPING PROCEDURE........................................................ 64 GENERAL................................................................................. 64 STEERING AND BRAKE SYSTEM............................................................... 64 Hookup.............................................................................. 64 HOIST SYSTEM............................................................................ 65 Hookup.............................................................................. 66 Dumping Procedure................................................................... 66 TOWING.................................................................................. 67 Towing Procedure.................................................................... 67 RESERVE ENGINE OIL SYSTEM (Optional).................................................... 68 Operation........................................................................... 68 WARNINGS AND CAUTIONS........................................................................... 69 TORQUE TABLES AND CONVERSION CHARTS ............................................................ 81 STORAGE PROCEDURES.............................................................................. 91 STORAGE AND IDLE MACHINE PREPARATION........................................................ 93 SHORT TERM IDLE PERIODS................................................................. 93 PREPARATION FOR STORAGE................................................................. 94 REMOVAL FROM STORAGE.................................................................... 95 RECONDITIONING AN IDLE VEHICLE.......................................................... 97 ENGINE OPERATION........................................................................ 99 AFTER ENGINE HAS STARTED................................................................ 100 ENGINE STORAGE.......................................................................... 101 Engine Storage-(Short Term)......................................................... 101 Engine Storage- (Long Term)......................................................... 102 TRANSMISSION PRESERVATION AND STORAGE................................................... 107 Restoring Transmission to Service................................................... 107 ELECTRIC DRIVE TRUCKS................................................................... 103 SECTION B STRUCTURES ............................................................................... 109 STRUCTURAL COMPONENTS........................................................................... 111 STRUCTURAL COMPONENTS....................................................................... 113 Preparation............................................................................. 113 LADDERS................................................................................. 114 Removal............................................................................. 115 Installation........................................................................ 115 RIGHT DECK.............................................................................. 115 Removal............................................................................. 115 Installation........................................................................ 116 LEFT DECK............................................................................... 116 Removal............................................................................. 116 Installation........................................................................ 117 CENTER DECK............................................................................. 117 DUMP BODY....................................................................................... 119 DUMP BODY................................................................................... 121 Removal................................................................................. 121 Installation............................................................................ 122 BODY PADS............................................................................... 123 Removal............................................................................. 123 Installation........................................................................ 123 Adjustment.......................................................................... 124 BODY GUIDE.............................................................................. 125 BODY-UP RETENTION CABLE................................................................. 126 BODY POSITION INDICATOR................................................................. 126 HOIST LIMIT SWITCH...................................................................... 126 BODY UP SWITCH.......................................................................... 126 ROCK EJECTORS........................................................................... 127 Inspection.......................................................................... 127 FUEL TANK....................................................................................... 129 FUEL TANK................................................................................... 130 Removal................................................................................. 130 Installation............................................................................ 130 Repair.................................................................................. 132 Cleaning................................................................................ 132 FUEL GAUGE SENDER....................................................................... 132 Removal............................................................................. 132 Installation........................................................................ 132 FUEL TANK BREATHER VALVE................................................................ 133 Disassembly......................................................................... 133 Assembly............................................................................ 133 FUEL RECEIVERS (WIGGINS QUICK FILL)..................................................... 133 FUEL RECEIVERS (WIGGINS QUICK FILL)..................................................... 134 SECTION C ENGINE ................................................................................... 135 POWER MODULE.................................................................................... 137 POWER MODULE................................................................................ 139 PREPARATION............................................................................. 139 Removal............................................................................. 139 Installation........................................................................ 144 COOLING SYSTEM.................................................................................. 149 COOLING SYSTEM DESCRIPTION.................................................................. 151 RADIATOR................................................................................ 152 Removal............................................................................. 152 Installation........................................................................ 155 Radiator Filling Procedure.......................................................... 156 REPAIRING THE RADIATOR...................................................................... 157 Internal Inspection..................................................................... 157 External Cleaning....................................................................... 157 Disassembly............................................................................. 157 Cleaning and Inspection................................................................. 158 Assembly................................................................................ 158 Pressure Testing........................................................................ 160 COOLANT SYSTEM TROUBLESHOOTING.............................................................. 160 POWER TRAIN..................................................................................... 161 ALTERNATOR REMOVAL PROCEDURE................................................................ 163 Removal (Komatsu SSDA16V160 or SDA16V160 Engine)........................................ 163 ENGINE/ALTERNATOR MATING.................................................................... 165 General Instructions.................................................................... 165 Measuring Procedure..................................................................... 165 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine........................... 167 ENGINE...................................................................................... 168 Removal................................................................................. 168 Service................................................................................. 169 Installation............................................................................ 169 AIR CLEANERS.................................................................................... 171 AIR CLEANERS................................................................................ 173 OPERATION............................................................................... 173 SERVICING THE AIR CLEANERS.............................................................. 173 Replacing The Filter Element........................................................ 174 AIR CLEANER ASSEMBLY CLEANING........................................................... 175 Main Filter Cleaning................................................................ 175 Precleaner Section Cleaning......................................................... 177 AIR INTAKE TROUBLESHOOTING.............................................................. 178 FAN CLUTCH ..................................................................................... 179 FAN CLUTCH.................................................................................. 181 REMOVAL & INSTALLATION TOOLING.......................................................... 181 DISASSEMBLY............................................................................. 184 CLEANING AND INSPECTION................................................................. 194 ASSEMBLY................................................................................ 198 TEST PROCEDURE.......................................................................... 212 SECTION D ELECTRICAL SYSTEM (24VDC) ................................................................ 213 24VDC ELECTRIC SUPPLY SYSTEM.................................................................... 215 24VDC ELECTRIC SUPPLY SYSTEM................................................................ 217 ELECTRICAL SYSTEM DESCRIPTION........................................................... 217 BATTERIES............................................................................... 217 Maintenance and Service............................................................. 217 Troubleshooting..................................................................... 217 BATTERY SUPPLY SYSTEM................................................................... 219 24VDC Battery Charging Alternator................................................... 219 Battery Box......................................................................... 219 Battery Control Box................................................................. 220 Battery Disconnect Switches......................................................... 220 24VDC Auxiliary Battery Receptacles................................................. 220 Isolator Diode...................................................................... 220 Engine Start Relay.................................................................. 220 24VDC to 12VDC Converter............................................................ 220 24 VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE).................................... 221 Operation........................................................................... 221 Pressure Switch..................................................................... 222 Check Valve......................................................................... 222 Timer Solenoid...................................................................... 222 MAINTENANCE............................................................................. 222 Prelube System Operation Checks..................................................... 222 Check Valve......................................................................... 222 Timer Solenoid...................................................................... 222 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT.............................................. 223 24 VDC ELECTRIC START SYSTEM................................................................ 225 CRANKING MOTORS......................................................................... 225 Operation........................................................................... 225 Removal............................................................................. 225 Installation........................................................................ 225 CRANKING MOTOR TROUBLESHOOTING.......................................................... 226 Preliminary Inspection.............................................................. 226 No-Load Test........................................................................ 226 Interpreting Results of Tests....................................................... 227 Disassembly......................................................................... 227 Cleaning and Inspection............................................................. 228 Armature Servicing.................................................................. 230 Field Coil Checks................................................................... 230 Field Coil Removal.................................................................. 230 SOLENOID CHECKS......................................................................... 231 Test................................................................................ 231 Assembly............................................................................ 232 Bearing Replacement:................................................................ 232 Motor Assembly:..................................................................... 232 Pinion Clearance.................................................................... 233 MAGNETIC SWITCH......................................................................... 233 Removal............................................................................. 233 Installation........................................................................ 233 Coil Test........................................................................... 234 24VDC ELECTRICAL SYSTEM COMPONENTS.............................................................. 235 24 VDC ELECTRICAL SYSTEM COMPONENTS......................................................... 237 TRUCK SHUTDOWN PROCEDURE................................................................ 237 BRAKE WARNING BUZZER.................................................................... 237 AUXILIARY CONTROL CABINET COMPONENTS.................................................... 237 Power Distribution Terminals........................................................ 237 Engine Starter Failure Delay Timer.................................................. 237 5 Minute Idle Timer................................................................. 238 Pulse Voltage Modulator (PMV)....................................................... 238 Control Power Relay................................................................. 238 Auto Lube Timer..................................................................... 238 Diode Board - DB1................................................................... 240 Fuse Blocks......................................................................... 241 Alarm Indicating Device (AID) System................................................ 241 Diode Matrix (With Sound)........................................................... 242 Diode Matrix (Without Sound)........................................................ 242 Hot Switch Inverter................................................................. 242 Hot Switch Inverter (Not Used)...................................................... 243 Temperature and Latch............................................................... 243 RELAY BOARDS............................................................................ 244 Relay Boards RB1, RB3, RB4, RB5..................................................... 244 Relay Board RB6, RB7, RB8, RB9...................................................... 245 Service............................................................................. 245 Relay Board Functions............................................................... 247 BODY-UP SWITCH.......................................................................... 249 Operation........................................................................... 249 Adjustment.......................................................................... 249 Service............................................................................. 249 HOIST LIMIT SWITCH...................................................................... 250 Operation........................................................................... 250 Adjustment.......................................................................... 250 Service............................................................................. 250 FUSE BLOCK CHARTS....................................................................... 251 CIRCUIT BREAKER CHART................................................................... 253 BATTERY CHARGING ALTERNATOR .................................................................... 255 BATTERY CHARGING SYSTEM..................................................................... 259 BATTERY CHARGING SYSTEM................................................................. 259 ELECTRICAL SYSTEM DESCRIPTION....................................................... 259 CHARGE VOLT AND AMP VALUES.......................................................... 259 BATTERY............................................................................. 259 Maintenance and Service......................................................... 259 Troubleshooting................................................................. 260 Undercharging................................................................... 260 Overcharging.................................................................... 260 Corrosion....................................................................... 260 Acid Levels..................................................................... 260 Non-Use or Storage.............................................................. 260 Freezing........................................................................ 261 BATTERY CHARGING ALTERNATOR............................................................. 262 GENERAL INFORMATION................................................................. 262 General Description............................................................. 262 Terminal Identification and Location............................................ 263 Battery Positive (B+)........................................................... 263 Battery Negative (B-)........................................................... 263 DC Output (D+).................................................................. 263 AC Output (R)................................................................... 263 Regulator Harness Plug Identification........................................... 263 Alternator Specifications....................................................... 263 Performance Curve............................................................... 263 Battery/Alternator Terminology.................................................. 264 WIRING DIAGRAM...................................................................... 266 DIMENSIONS AND TORQUE VALUES........................................................ 267 PERIODIC MAINTENANCE................................................................ 268 TESTING................................................................................. 268 GENERAL INFORMATION................................................................. 268 Troubleshooting Alternator (On-Truck)........................................... 268 Equipment Required.............................................................. 268 Preliminary Checks.............................................................. 268 Test Set-up..................................................................... 270 Test Procedure.................................................................. 271 REGULATOR TESTING................................................................... 272 Regulator Bypass Test (No Output)............................................... 272 Regulator Bypass Test (Amp Rating).............................................. 273 BENCH TESTING....................................................................... 274 Equipment....................................................................... 274 Identification Record........................................................... 274 Advanced Troubleshooting........................................................ 274 Bench Test 1: No-Load Test...................................................... 274 Bench Test 2: Full Load Test.................................................... 275 Bench Test 3: Regulator Bypass Test............................................. 275 STATIC TESTING...................................................................... 276 Equipment....................................................................... 276 Identification Record........................................................... 276 Regulator Tester................................................................ 276 Check For Shorted Power Transistor.............................................. 276 Circuit Tests................................................................... 277 FIELD COIL TESTS.................................................................... 278 Field Coil Test 1: Check for Open or Shorted Field Coil......................... 278 Field Coil Test 2: Check For Grounded Field Coil................................ 278 STATOR TESTS........................................................................ 279 Stator Test 1: Check For Stator-To-Stator Continuity............................ 279 Stator Test 2: Check For Grounded Stators....................................... 280 THERMAL SWITCH TEST................................................................. 280 Initial Test.................................................................... 280 Verifying a Faulty Thermal Switch............................................... 281 TROUBLESHOOTING TIPS................................................................ 282 ALTERNATOR.............................................................................. 286 ALTERNATOR REPAIR................................................................... 286 Removal......................................................................... 286 Installation.................................................................... 288 Special Tools and Lubricants.................................................... 288 Epoxy Adhesive.................................................................. 289 Liquid Threadlockers............................................................ 289 Elastoplastic Silicone Resin.................................................... 289 ALTERNATOR EXPLODED VIEW............................................................ 291 ALTERNATOR DISASSEMBLY.............................................................. 293 Regulator Removal............................................................... 293 Fan Removal..................................................................... 294 Pulley Removal.................................................................. 295 Anti-Drive End Housing Removal.................................................. 295 Anti-Drive End Rotor Removal.................................................... 297 Drive End Housing Removal....................................................... 299 Drive End Rotor Removal......................................................... 305 Field Coil Removal.............................................................. 306 Drive End and/or Anti-Drive End Stator Removal.................................. 308 CLEANING AND INSPECTION............................................................. 310 ALTERNATOR ASSEMBLY................................................................. 310 Anti-Drive End Stator Installation.............................................. 310 Drive End Stator Installation................................................... 312 Field Coil Installation......................................................... 315 Drive End Bearing Installation.................................................. 317 Drive End Rotor Installation.................................................... 319 Rotor and Rotor Shaft Installation.............................................. 319 Drive End Housing Installation.................................................. 320 Anti-Drive End Rotor Installation............................................... 324 Anti-Drive End Housing Installation............................................. 325 Regulator Installation.......................................................... 328 THERMAL SWITCH...................................................................... 329 Removal......................................................................... 329 Installation.................................................................... 331 SUPPORT STAND....................................................................... 331 KOMTRAX Plus COMPONENTS......................................................................... 333 KOMTRAX Plus COMPONENTS..................................................................... 335 KOMTRAX Plus BASIC FEATURES............................................................. 335 Gather Data......................................................................... 335 Convert and Record Data............................................................. 335 Communicate Data to Off-Board Systems............................................... 336 USING THE KOMTRAX Plus SYSTEM........................................................... 337 Turning the KOMTRAX Plus System ON.................................................. 337 Normal KOMTRAX Plus Operation....................................................... 337 Turning the KOMTRAX Plus System OFF................................................. 338 Downloading from the KOMTRAX Plus Controller........................................ 338 KOMTRAX Plus DATA ITEMS................................................................. 339 Fault Codes......................................................................... 339 Machine History..................................................................... 339 KOMTRAX Plus History................................................................ 339 Snapshots........................................................................... 340 Manual Snapshots.................................................................... 340 Trends.............................................................................. 342 Histogram (Load Map) Data........................................................... 342 Haul Cycle Data..................................................................... 343 Alarm and Snapshot Triggers......................................................... 344 Satellite Features.................................................................. 344 KOMTRAX Plus DIAGNOSTIC FEATURES........................................................ 346 Fault History....................................................................... 346 KOMTRAX Plus LED Digits............................................................. 346 KOMTRAX Plus CONTROLLER................................................................. 346 Removal............................................................................. 347 Installation........................................................................ 347 ORBCOMM CONTROLLER...................................................................... 348 Removal............................................................................. 348 Installation........................................................................ 348 INTERFACE MODULE........................................................................ 349 Removal............................................................................. 349 Installation........................................................................ 349 SENSORS................................................................................. 350 Temperature Sensors................................................................. 350 Pressure Sensors.................................................................... 350 KOMTRAX Plus SOFTWARE........................................................................... 351 KOMTRAX Plus SOFTWARE....................................................................... 353 NECESSARY SOFTWARE...................................................................... 353 NECESSARY TOOLS......................................................................... 353 KOMTRAX Plus SYSTEM SET UP.............................................................. 354 INTERFACE MODULE.................................................................... 354 KOMTRAX Plus CONTROLLER............................................................. 354 INTERFACE MODULE........................................................................ 354 FLASHBURN PROGRAM................................................................... 354 Installation.................................................................... 354 INTERFACE MODULE APPLICATION CODE................................................... 354 Installation.................................................................... 354 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM............................. 355 Installation.................................................................... 355 Using The Program............................................................... 355 KOMTRAX Plus CONTROLLER................................................................. 355 KOMTRAX Plus TOOL BOX............................................................... 355 Installation.................................................................... 355 KOMTRAX Plus SETTING TOOL........................................................... 355 Installation.................................................................... 355 KOMTRAX Plus INITIALIZATION PROCEDURE................................................... 356 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE.......................................... 356 VHMS Setting Tool software program.............................................. 356 Select Operation................................................................ 356 VHMS Setting Function........................................................... 357 Machine Information Setting(1).................................................. 357 Machine Information Setting(2).................................................. 357 Date & Time Setting............................................................. 357 GCC Setting..................................................................... 358 Setting Summary................................................................. 358 2. KOMTRAX Plus SNAPSHOT PROCEDURE.................................................. 359 3. KOMTRAX Plus DOWNLOAD PROCEDURE.................................................. 360 4. LOCATION OF DOWNLOAD FILES....................................................... 360 5. KOMTRAX Plus FTP UPLOAD PROCEDURE................................................ 361 6. KOMTRAX Plus INITIALIZATION FORMS................................................ 362 WHEN REPLACING A KOMTRAX Plus CONTROLLER................................................ 363 To Set: Date & Time; Satellite; Payload Meter....................................... 365 Review Setting Information.......................................................... 367 KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING....................................................... 369 INTERFACE MODULE AND KOMTRAX Plus CHECKOUT & TROUBLESHOOTING................................ 371 GENERAL................................................................................. 371 Structure and Purpose............................................................... 371 INTERFACE MODULE CHECKOUT............................................................... 372 Interface Module.................................................................... 372 Necessary Equipment:................................................................ 372 Preliminary......................................................................... 373 Checking Inputs And Outputs From The Interface Module............................... 373 Check Analog Inputs To The Interface Module......................................... 376 Check CAN RPC & J1939 Interfaces To The IM.......................................... 377 Check Outputs From The Interface Module............................................. 377 KOMTRAX Plus CONTROLLER CHECKOUT........................................................ 378 KOMTRAX Plus Controller............................................................. 378 Necessary Equipment:................................................................ 378 Preliminary......................................................................... 379 KOMTRAX Plus Controller Checkout Procedure.......................................... 380 ORBCOMM CONTROLLER...................................................................... 382 TROUBLESHOOTING......................................................................... 382 Communications Networks............................................................. 382 Coaxial Cable....................................................................... 382 FAULT CODES............................................................................. 383 Fault History....................................................................... 383 KOMTRAX Plus LED Display Fault Codes................................................ 384 Chassis Fault Codes................................................................. 385 Engine Fault Codes.................................................................. 388 FAULT TREE ANALYSIS..................................................................... 394 Unable to connect to KOMTRAX Plus from laptop PC.................................... 394 Flashing Error Code N4-23 (PLM III Communications Fault)............................ 395 Flashing Error Code N4-22 (Engine Communications Fault)............................. 396 No Data Received By WebCARE......................................................... 397 Coaxial Cable Troubleshooting....................................................... 398 KOMTRAX PLUS FORMS ............................................................................. 399 KOMTRAX PLUS FORMS.......................................................................... 401 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 401 KOMTRAX PLUS DATA DOWNLOAD.............................................................. 402 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 403 KOMTRAX PLUS INITIALIZATION FORM........................................................ 405 SECTION E ELECTRIC PROPULSION SYSTEM ............................................................... 407 ELECTRIC PROPULSION SYSTEM COMPONENTS .......................................................... 409 ELECTRICAL PROPULSION SYSTEM COMPONENTS..................................................... 411 GENERAL SYSTEM DESCRIPTION.............................................................. 411 SYSTEM COMPONENTS....................................................................... 413 Propulsion System Controller (PSC).................................................. 413 Truck Control Interface (TCI)....................................................... 414 Diagnostic Information Display (DID) Panel.......................................... 415 DID Panel Event Codes............................................................... 415 PSC SOFTWARE FUNCTIONS.................................................................. 434 Input Processing.................................................................... 434 State Machine....................................................................... 434 DC Link State....................................................................... 437 Engine Control...................................................................... 438 ALTERNATOR FIELD CONTROL................................................................ 438 Desired Three-Phase Voltage......................................................... 438 Desired DC Link Voltage............................................................. 438 Self-Load........................................................................... 439 Propel Torque Control............................................................... 439 Retard Torque Control............................................................... 439 Wheel Slide Control................................................................. 440 Resistor Grid Control............................................................... 440 Chopper Voltage Control............................................................. 440 EVENT DETECTION AND PROCESSING.......................................................... 440 Power-On Tests...................................................................... 440 Initiated Tests..................................................................... 441 Periodic Tests...................................................................... 441 EVENT RESTRICTIONS...................................................................... 441 EVENT LOGGING AND STORAGE............................................................... 441 Event History Buffer................................................................ 442 Data Packs.......................................................................... 442 To Record and Save a Data Pack to a Disk............................................ 442 Event Reset......................................................................... 443 SERIAL DATA COMMUNICATIONS.............................................................. 443 PSC - TCI Communications Processing................................................. 443 PSC - PTU Communications Processing................................................. 443 Inverter Communications Processing.................................................. 444 OUTPUT PROCESSING....................................................................... 444 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS................................................ 444 Fast Start.......................................................................... 444 Engine Shutdown/Engine Not Running.................................................. 444 Limp Home Mode...................................................................... 445 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS................................... 446 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 454 Removal............................................................................. 454 Installation........................................................................ 454 Disassembly......................................................................... 454 Assembly............................................................................ 454 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE .................................................. 455 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................................... 457 AC DRIVE SYSTEM MAINTENANCE............................................................. 457 NORMAL TRUCK SHUTDOWN PROCEDURE......................................................... 458 SHUTDOWN AFTER SYSTEM FAILURE........................................................... 458 SYSTEM CHECKOUT......................................................................... 459 Battery and Control Circuit Checks - Battery Power OFF.............................. 459 Battery and Control Circuit Checks - Battery Power ON............................... 462 Checks with Key Switch OFF.......................................................... 463 Checks with Key Switch ON........................................................... 463 CPU Battery Checks.................................................................. 463 MEMORY BACKUP BATTERY REPLACEMENT....................................................... 464 TCI PROGRAMMING......................................................................... 464 PSC PROGRAMMING......................................................................... 465 INVERTER PROGRAMMING.................................................................... 465 CPU RESET............................................................................... 465 PSC CHECKOUT............................................................................ 466 PSC Digital Input Checks............................................................ 466 PSC Digital Output Checks........................................................... 470 TCI CHECKOUT............................................................................ 471 Modular Mining Communication Port Check............................................. 471 TCI Digital Input Checks............................................................ 471 TCI Digital Output Tests............................................................ 477 CALIBRATIONS............................................................................ 479 Speedometer......................................................................... 479 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial................................ 479 ERASING EVENTS.......................................................................... 479 PSC................................................................................. 479 TCI................................................................................. 480 GATE DRIVER POWER CONVERTER TEST........................................................ 480 LOAD TESTING............................................................................ 481 Preparation......................................................................... 481 Alternator Speed Sensor Checks...................................................... 481 Battery Boost Check................................................................. 481 Brake Circuit Switch Checks......................................................... 482 Hoist & Steering Circuit Switch Checks.............................................. 482 Link Energized Checks............................................................... 482 Loadbox Test........................................................................ 484 TROUBLESHOOTING......................................................................... 488 PVM Optimum Load Curve Handshaking Troubleshooting.................................. 488 Phase Module and Chopper Module Troubleshooting..................................... 488 PHASE MODULE REPLACEMENT................................................................ 489 Phase Module Removal................................................................ 489 Phase Module Installation........................................................... 489 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS .......................................................... 491 TIRES AND RIMS.................................................................................. 493 TIRES AND RIMS.............................................................................. 495 FRONT TIRES AND RIMS.................................................................... 495 Removal............................................................................. 495 Installation........................................................................ 497 REAR TIRES AND RIMS..................................................................... 497 Removal............................................................................. 497 Installation........................................................................ 498 RIM AND TIRE............................................................................ 500 Tire Removal........................................................................ 500 Rim And Tire Preparation............................................................ 500 Lubricants.......................................................................... 501 Tire Installation................................................................... 501 FRONT WHEEL HUB AND SPINDLES.................................................................... 503 FRONT WHEEL HUB AND SPINDLE................................................................. 505 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 505 Removal............................................................................. 505 Spindle Removal Procedure (Optional) (off of the truck)............................. 508 Installation........................................................................ 510 Disassembly......................................................................... 513 Cleaning and Inspection............................................................. 513 Assembly............................................................................ 514 Wheel Bearing Adjustment (Tire Removed)............................................. 516 Wheel Bearing Adjustment (Tire mounted)............................................. 517 OIL SAMPLING PROCEDURE.................................................................. 518 Oil Sampling Guidelines............................................................. 519 Procedure........................................................................... 519 OIL DRAIN AND REFILL PROCEDURE.......................................................... 519 STEERING CYLINDERS AND TIE ROD.......................................................... 520 Spherical Bearing Wear Limits....................................................... 520 Installation........................................................................ 521 Bearing Replacement (Steering cylinder and tie rod)................................. 521 TIE ROD................................................................................. 523 Removal............................................................................. 523 Installation........................................................................ 523 Assembly............................................................................ 524 TOE-IN ADJUSTMENT....................................................................... 525 REAR AXLE HOUSING ATTACHMENT.................................................................... 527 REAR AXLE HOUSING ATTACHMENT................................................................ 529 PIVOT PIN............................................................................... 529 Removal............................................................................. 529 Installation........................................................................ 529 PIVOT EYE BEARING....................................................................... 530 Disassembly......................................................................... 530 Assembly............................................................................ 530 PIVOT EYE REPAIR........................................................................ 531 Removal............................................................................. 531 Installation........................................................................ 531 Disassembly......................................................................... 531 Assembly............................................................................ 531 ANTI-SWAY BAR........................................................................... 532 Removal............................................................................. 532 Installation........................................................................ 532 Disassembly......................................................................... 532 Cleaning and Inspection............................................................. 532 Assembly............................................................................ 532 REAR AXLE HOUSING............................................................................... 533 REAR AXLE HOUSING........................................................................... 535 REAR AXLE HOUSING....................................................................... 535 Removal............................................................................. 535 Installation........................................................................ 535 WHEEL MOTOR............................................................................. 536 Removal............................................................................. 536 Cleaning and Inspection............................................................. 536 Installation........................................................................ 537 WHEEL MOTOR GEAR OIL.................................................................... 540 Change/Filter The Gear case Oil..................................................... 540 Oil................................................................................. 540 Remove And Clean Magnetic Plugs..................................................... 540 Flushing The Gearbox................................................................ 540 Check Gear Case Oil Level........................................................... 540 SECTION H SUSPENSIONS .............................................................................. 541 FRONT SUSPENSION................................................................................ 543 FRONT SUSPENSION............................................................................ 545 Removal................................................................................. 545 Installation............................................................................ 546 TURN-OF-THE-NUT Tightening Procedure.................................................... 548 Upper Mounting Joint - 60° Advance.................................................. 548 Lower Mounting Joint - 90° Advance.................................................. 550 Inspection.......................................................................... 550 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)..................................... 551 Bearing Structure Removal........................................................... 551 Bearing Structure Installation...................................................... 551 MAJOR SUSPENSION REBUILD................................................................ 552 Disassembly......................................................................... 552 Assembly............................................................................ 553 PRESSURE TEST........................................................................... 555 REAR SUSPENSIONS ............................................................................... 557 REAR SUSPENSIONS............................................................................ 559 Removal................................................................................. 559 Installation............................................................................ 562 ROD UP SUSPENSION....................................................................... 564 Disassembly......................................................................... 564 Cleaning and Inspection............................................................. 564 Assembly............................................................................ 564 ROD DOWN SUSPENSION..................................................................... 566 Disassembly......................................................................... 566 Cleaning and Inspection............................................................. 566 Assembly............................................................................ 568 PRESSURE TEST........................................................................... 570 Suspension pressure test............................................................ 570 OILING AND CHARGING PROCEDURE................................................................... 571 OILING AND CHARGING PROCEDURE............................................................... 573 GENERAL................................................................................. 573 EQUIPMENT LIST.......................................................................... 573 HYDRAIR® CHARGING KIT................................................................... 574 Installation of Charging Kit........................................................ 574 Removal of Charging Kit............................................................. 574 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................................... 575 FRONT SUSPENSION........................................................................ 575 Front Suspension Oiling............................................................. 575 Front Suspension Nitrogen Charging.................................................. 577 REAR SUSPENSION - ROD UP................................................................ 579 Rear Suspension Oiling (Rod Up Only)................................................ 579 Rear Suspension Nitrogen Charging (Rod Up Only)..................................... 580 REAR SUSPENSION - ROD DOWN.............................................................. 582 Rear Suspension Oiling (Rod Down Only).............................................. 582 Rear Suspension Nitrogen Charging (Rod Down Only)................................... 584 OIL AND NITROGEN SPECIFICATIONS CHART................................................... 586 SECTION J BRAKE CIRCUIT ............................................................................ 587 BRAKE CIRCUIT................................................................................... 589 BRAKE CIRCUIT............................................................................... 591 OPERATION............................................................................... 591 SERVICE BRAKE CIRCUIT OPERATION......................................................... 591 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 593 PARKING BRAKE CIRCUIT................................................................... 593 Normal Operation (key switch on, engine running).................................... 593 BRAKE LOCK CIRCUIT...................................................................... 594 WARNING CIRCUIT......................................................................... 594 BRAKE CIRCUIT COMPONENT SERVICE................................................................. 597 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 599 BRAKE VALVE............................................................................. 599 Rebuild Criteria.................................................................... 599 Removal............................................................................. 599 Installation........................................................................ 601 DISASSEMBLY............................................................................. 603 Cleaning and Inspection............................................................. 605 ASSEMBLY................................................................................ 605 Actuator Base Threaded Inserts...................................................... 605 Boot and Cap........................................................................ 605 Valve Body Seal Installation........................................................ 606 Regulator Sleeve O-Ring Installation................................................ 606 Actuator Plunger O-ring Installation................................................ 607 Assembly of Valve................................................................... 607 VALVE BENCH TEST AND ADJUSTMENT......................................................... 609 Test Set Up Procedure............................................................... 610 Brake Valve Output Pressure Adjustment.............................................. 610 Final Test and Adjustment........................................................... 611 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 612 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal).... 614 Installation of Retard Pedal To Brake Pedal......................................... 614 HYDRAULIC BRAKE ACCUMULATORS............................................................ 615 Brake Accumulator Bleed Down Procedure.............................................. 615 Removal............................................................................. 615 Installation........................................................................ 615 Disassembly......................................................................... 615 Cleaning and Inspection............................................................. 617 Assembly............................................................................ 617 Charging Procedure.................................................................. 619 BRAKE MANIFOLD.......................................................................... 620 Removal............................................................................. 620 Removal............................................................................. 620 Installation........................................................................ 621 Disassembly......................................................................... 621 Cleaning and Inspection............................................................. 622 Assembly............................................................................ 622 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................... 623 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 625 EQUIPMENT REQUIRED...................................................................... 626 INITIAL SYSTEM SET-UP................................................................... 628 PARKING BRAKE........................................................................... 628 BRAKE SYSTEM CHECK-OUT.................................................................. 629 BRAKE LOCK.............................................................................. 629 FAILURE MODES CHECK-OUT................................................................. 630 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 631 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 634 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 635 FRONT BRAKES.................................................................................... 637 WHEEL SPEED FRONT DISC BRAKES............................................................... 639 BRAKE CALIPER........................................................................... 639 Caliper Removal..................................................................... 639 Installation........................................................................ 640 Disassembly......................................................................... 641 Assembly............................................................................ 641 Cleaning and Inspection............................................................. 642 BRAKE LINING............................................................................ 643 Replacement......................................................................... 643 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................. 645 GENERAL............................................................................. 645 Safety Precautions.............................................................. 645 Front Brake Conditioning........................................................ 645 BRAKE BLEEDING PROCEDURES............................................................... 646 ARMATURE SPEED REAR DISC BRAKES................................................................. 647 ARMATURE SPEED REAR DISC BRAKES............................................................. 649 REAR BRAKES............................................................................. 649 CALIPER AND DISC.................................................................... 649 Removal......................................................................... 649 Installation.................................................................... 651 PARK BRAKE ADJUSTMENT PROCEDURE..................................................... 653 BRAKE BLEEDING PROCEDURE............................................................ 654 Service Brake................................................................... 654 Park Brake...................................................................... 654 CALIPER............................................................................. 655 Disassembly..................................................................... 655 PISTON SUBASSEMBLY.................................................................. 658 Disassembly..................................................................... 658 PREPARATION FOR ASSEMBLY............................................................ 659 Clean Parts..................................................................... 659 For Rough Metal Parts........................................................... 660 Dry and Inspect Parts........................................................... 660 Corrosion Protection............................................................ 660 INSPECTION.......................................................................... 660 Caliper Parts................................................................... 660 Shoes, Linings and End Plates................................................... 661 Inspect linings................................................................. 661 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC).................... 661 Piston Assembly Adjuster Grip Force............................................. 662 Adjuster Force.................................................................. 664 Piston Return Spring............................................................ 666 ASSEMBLY............................................................................ 667 Adjuster and Pin Assembly....................................................... 667 Piston Subassembly.............................................................. 668 Brake Caliper................................................................... 669 PERIODIC INSPECTIONS................................................................ 675 Shoes, Linings and End Plates................................................... 675 Inspect the following areas for fluid leaks..................................... 675 Dust Boots...................................................................... 675 Brake Disc...................................................................... 675 BRAKE LINING........................................................................ 676 Replacement..................................................................... 676 BRAKE DISC.......................................................................... 676 Inspection...................................................................... 676 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................... 677 GENERAL......................................................................... 677 SAFETY PRECAUTIONS.............................................................. 677 Rear Brake Conditioning..................................................... 678 SECTION L HYDRAULIC SYSTEM......................................................................... 681 HYDRAULIC SYSTEM................................................................................ 683 HYDRAULIC SYSTEM............................................................................ 685 HYDRAULIC SYSTEM OPERATION.............................................................. 685 COMPONENT DESCRIPTION................................................................... 686 Hoist Pump.......................................................................... 686 Steering/Brake Pump................................................................. 686 Tank................................................................................ 686 High Pressure Hydraulic Filters..................................................... 686 Bleeddown Manifold.................................................................. 686 Steering System Accumulators........................................................ 686 DISABLED TRUCK CONNECTORS............................................................... 688 GENERAL............................................................................. 688 STEERING AND BRAKE SYSTEM........................................................... 688 Hookup.......................................................................... 688 HOIST SYSTEM........................................................................ 689 Hookup.......................................................................... 689 Dumping Procedure............................................................... 689 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................... 691 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 693 HOIST PUMP.............................................................................. 693 Removal............................................................................. 693 Installation........................................................................ 694 Disassembly......................................................................... 696 Inspection Of Parts................................................................. 699 Assembly............................................................................ 700 HYDRAULIC TANK.......................................................................... 706 Filling Instructions................................................................ 706 Removal............................................................................. 706 Installation........................................................................ 707 HYDRAULIC TANK STRAINERS................................................................ 708 Removal............................................................................. 708 Inspect and Clean................................................................... 708 Installation........................................................................ 709 HYDRAULIC TANK BREATHERS................................................................ 709 HOIST CIRCUIT FILTERS................................................................... 710 FILTER ELEMENT REPLACEMENT.............................................................. 711 Removal............................................................................. 711 Installation........................................................................ 711 INDICATOR SWITCH........................................................................ 711 STEERING CIRCUIT................................................................................ 713 STEERING CIRCUIT............................................................................ 715 STEERING CIRCUIT OPERATION.............................................................. 715 COMPONENT DESCRIPTION................................................................... 716 STEERING CONTROL UNIT............................................................... 716 FLOW AMPLIFIER...................................................................... 716 No Steer........................................................................ 718 Steering Left................................................................... 720 Steering Right.................................................................. 722 No Steer, External Shock Load................................................... 724 BLEED DOWN MANIFOLD................................................................. 726 ACCUMULATORS........................................................................ 727 Low Precharge Warning Switch.................................................... 727 HIGH PRESSURE FILTER................................................................ 727 STEERING/BRAKE PUMP................................................................. 727 Operation....................................................................... 728 PRINCIPLE OF OPERATION.............................................................. 730 Full Pump Volume:............................................................... 730 Half Pump Volume:............................................................... 730 Neutral Position:............................................................... 731 STEERING CIRCUIT COMPONENT REPAIR............................................................... 733 STEERING CIRCUIT COMPONENT REPAIR........................................................... 735 BLEED DOWN MANIFOLD..................................................................... 735 Removal............................................................................. 735 Installation........................................................................ 735 ACCUMULATOR............................................................................. 736 Removal............................................................................. 736 Installation........................................................................ 737 Disassembly......................................................................... 737 Cleaning and Inspection............................................................. 738 Assembly............................................................................ 738 LEAK TESTING............................................................................ 740 STEERING ACCUMULATOR CHARGING PROCEDURE................................................. 741 Temperature During Precharge........................................................ 744 ACCUMULATOR STORAGE PROCEDURES.......................................................... 744 Instructions For Storing Bladder Accumulators....................................... 744 Installation........................................................................ 745 Bladder Storage Procedures.......................................................... 745 FLOW AMPLIFIER.......................................................................... 746 Removal............................................................................. 746 Installation........................................................................ 746 Disassembly......................................................................... 748 Reassembly.......................................................................... 749 STEERING CONTROL UNIT................................................................... 750 Removal............................................................................. 750 Spline Inspection................................................................... 750 Installation........................................................................ 751 Disassembly......................................................................... 751 Cleaning and Inspection............................................................. 752 Assembly............................................................................ 753 STEERING CYLINDER....................................................................... 757 Disassembly......................................................................... 757 Inspection and Cleaning............................................................. 757 Assembly............................................................................ 757 STEERING CIRCUIT FILTER................................................................. 758 Filter Element Replacement.......................................................... 758 Removal............................................................................. 759 Installation........................................................................ 759 Indicator Switch.................................................................... 759 STEERING AND BRAKE PUMP................................................................. 760 Removal............................................................................. 760 Installation........................................................................ 761 Disassembly......................................................................... 762 Control Piston Group................................................................ 762 Valve Plate Group................................................................... 763 Rotating Group...................................................................... 763 Swashblock Group.................................................................... 764 Driveshaft Group.................................................................... 764 INSPECTION.............................................................................. 764 Control Piston Group................................................................ 764 Valve Plate Group................................................................... 764 Rotating Group...................................................................... 764 Swashblock Group.................................................................... 768 Driveshaft Group.................................................................... 768 Compensator Block and Unloader Module............................................... 768 Stroke Adjuster Assembly............................................................ 768 ASSEMBLY................................................................................ 768 Swashblock Group.................................................................... 768 Control Piston Group................................................................ 770 Valve Plate Group................................................................... 771 HOIST CIRCUIT................................................................................... 773 HOIST CIRCUIT............................................................................... 775 HOIST CIRCUIT OPERATION................................................................. 775 COMPONENT DESCRIPTION................................................................... 776 Hydraulic Tank...................................................................... 776 Hoist Pump.......................................................................... 776 High Pressure Filters............................................................... 776 Hoist Valve......................................................................... 777 Hoist Pilot Valve................................................................... 778 Hoist-up Limit Solenoid............................................................. 778 Pilot Operated Check Valve.......................................................... 778 Counterbalance Valve Manifold....................................................... 779 HOIST SYSTEM OPERATION MODES............................................................ 780 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)........................ 780 Power Up Operation (Figure 7-7)..................................................... 782 Hold Operation (Figure 7-8)......................................................... 784 Power Down Operation (Figure 7-9)................................................... 786 Float Operation (Figure 7-10)....................................................... 788 HOIST CIRCUIT COMPONENT REPAIR.................................................................. 791 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 793 HOIST VALVE............................................................................. 793 Removal............................................................................. 793 Installation........................................................................ 793 O-Ring Replacement.................................................................. 794 INLET SECTION........................................................................... 795 Disassembly......................................................................... 795 Cleaning and Inspection............................................................. 796 Assembly............................................................................ 796 SPOOL SECTION........................................................................... 796 Disassembly......................................................................... 796 Cleaning and Inspection............................................................. 799 Assembly............................................................................ 799 HOIST PILOT VALVE....................................................................... 800 Removal............................................................................. 800 Installation........................................................................ 800 Disassembly......................................................................... 801 Cleaning and Inspection............................................................. 802 Assembly............................................................................ 803 BODY UP LIMIT SOLENOID.................................................................. 804 PILOT OPERATED CHECK VALVE.............................................................. 804 HOIST CYLINDERS......................................................................... 804 Removal............................................................................. 804 Installation........................................................................ 805 Disassembly......................................................................... 806 Cleaning and Inspection............................................................. 808 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 809 Quill Installation.................................................................. 809 Installation of Check Balls and Plugs in Quill...................................... 810 Assembly of Cylinder................................................................ 811 Assembly of Cylinder................................................................ 811 Pressure Testing.................................................................... 812 OVERCENTER MANIFOLD..................................................................... 813 HYDRAULIC CHECKOUT PROCEDURE.................................................................... 815 HYDRAULIC CHECKOUT PROCEDURE................................................................ 817 STEERING AND BRAKE PUMP................................................................. 817 Pressure Check And Adjustment Procedure............................................. 817 BLEEDDOWN MANIFOLD...................................................................... 819 SHOCK & SUCTION VALVES.................................................................. 819 Shock & Suction Valve Settings...................................................... 819 LEAKAGE TESTS........................................................................... 821 Steering Control Unit & Flow Amplifier.............................................. 821 Bleeddown Manifold.................................................................. 821 ACCUMULATOR BLEED DOWN PROCEDURE........................................................ 823 LOW STEERING PRESSURE SWITCH............................................................ 823 CHECKING HOIST SYSTEM PRESSURES......................................................... 830 Hoist System Relief Pressure Adjustment............................................. 830 Power Down Relief Pressure Adjustment............................................... 831 HOIST COUNTERBALANCE VALVE.......................................................... 832 Preparation:.................................................................... 832 Counterbalance Valve Pressure Check Only:....................................... 832 Counterbalance Valve Adjustment................................................. 833 HYDRAULIC SYSTEM FLUSHING PROCEDURE..................................................... 836 Hydraulic System Flushing Procedure................................................. 836 OIL CLEANLINESS CHECK............................................................... 841 SECTION M SPECIAL TOOLS ............................................................................ 843 HEATER OPTIONS ................................................................................. 845 GENERAL INFORMATION......................................................................... 847 TROUBLESHOOTING............................................................................. 847 HEATER ELEMENT.............................................................................. 847 Removal................................................................................. 847 Installation............................................................................ 848 GENERAL..................................................................................... 849 Maintenance............................................................................. 849 HEATING ELEMENT............................................................................. 849 Removal................................................................................. 849 Installation............................................................................ 850 THERMOSTAT.................................................................................. 850 Removal................................................................................. 850 Installation............................................................................ 850 GENERAL INFORMATION......................................................................... 851 TROUBLESHOOTING............................................................................. 851 HEATER ELEMENT.............................................................................. 851 Removal................................................................................. 851 Installation............................................................................ 852 SPECIAL TOOLS................................................................................... 853 NITROGEN CHARGING VALVE..................................................................... 853 ROLL-OUT ASSEMBLY........................................................................... 853 EYE BOLT.................................................................................... 853 OFFSET WRENCH............................................................................... 854 TORQUE ADAPTER.............................................................................. 854 HANDLE...................................................................................... 854 SEAL INSTALLER.............................................................................. 854 SLEEVE ALIGNMENT TOOLS...................................................................... 855 QUICK DISCONNECT COUPLING................................................................... 855 HARNESS..................................................................................... 855 SEAL INSTALLATION RING...................................................................... 855 BELT TENSION TESTER......................................................................... 856 BELT ALIGNMENT TOOL......................................................................... 856 SOCKETS AND ADAPTERS........................................................................ 856 DUST CAPS................................................................................... 856 HYDRAULIC SYSTEM FLUSHING TOOLS............................................................. 857 PAYLOAD DATA MANAGER........................................................................ 857 HYDRAULIC SYSTEM VACUUM PUMP................................................................ 857 MISCELLANEOUS SERVICE TOOLS................................................................. 858 BRAKE PISTON TOOL........................................................................... 859 HIGH VOLTAGE TOOLS.......................................................................... 862 2000 VDC METER.............................................................................. 862 GROUNDING STICKS............................................................................ 862 BODY PAD SPACER TOOL........................................................................ 863 RADIATOR SHUTTERS .............................................................................. 865 RADIATOR SHUTTERS........................................................................... 867 OPERATION............................................................................... 867 Hydraulic Circuit................................................................... 867 Electrical Circuit:................................................................. 868 MAINTENANCE AND REPAIR.................................................................. 868 TROUBLESHOOTING......................................................................... 869 Hydraulic Troubleshooting........................................................... 872 Electrical Troubleshooting.......................................................... 874 PAYLOAD METER III ™ ........................................................................... 875 OPERATION SECTION........................................................................... 879 Introduction............................................................................ 879 Data Summary........................................................................ 879 Data Gathering...................................................................... 879 COMPONENT DESCRIPTION................................................................... 880 System Diagram...................................................................... 880 Suspension Pressure Sensors......................................................... 880 Inclinometer........................................................................ 880 Operator Display.................................................................... 880 Operator Switch..................................................................... 881 Speed Input......................................................................... 881 Body-Up Switch...................................................................... 881 Brake Lock Switch................................................................... 881 Payload Meter....................................................................... 881 Communications Ports................................................................ 881 Key Switch Input.................................................................... 882 Payload Meter Power................................................................. 882 Load Lights......................................................................... 882 Wiring and Termination.............................................................. 883 TCI Outputs......................................................................... 883 OPERATOR’S DISPLAY AND SWITCH........................................................... 884 Reading the Speedometer............................................................. 884 Reading the Load Display............................................................ 884 Using the Operator ID............................................................... 884 Using the Load and Ton Counter...................................................... 884 Total Ton Counter................................................................... 884 Total Load Counter.................................................................. 885 Clearing the Counters............................................................... 885 Viewing Live Sensor Data............................................................ 885 Other Display Messages.............................................................. 885 PAYLOAD OPERATION & CALCULATION......................................................... 886 Description of Haul Cycle States.................................................... 886 Haul Cycle Description.............................................................. 886 Load Calculation.................................................................... 887 Carry Back.......................................................................... 887 Measurement Accuracy................................................................ 887 SOURCES FOR PAYLOAD ERROR............................................................... 887 Payload Error....................................................................... 887 Loading Conditions.................................................................. 888 Pressure Sensors.................................................................... 888 Swingloads.......................................................................... 888 Speed and Distance.................................................................. 888 HAUL CYCLE DATA......................................................................... 888 Haul Cycle Warning Flags............................................................ 890 Frame Torque Data................................................................... 891 Sprung Weight Data.................................................................. 891 Maximum Speed Data.................................................................. 891 Alarm Records....................................................................... 891 Fault Code Data..................................................................... 892 PC SOFTWARE OVERVIEW.................................................................... 893 System Configuration................................................................ 893 Installing the PLMIII Software...................................................... 893 DOWNLOADING DATA........................................................................ 894 PLM III SYSTEM CONFIGURATION............................................................ 895 Starting Communications............................................................. 895 Displayed Payload Units............................................................. 895 Time Units.......................................................................... 895 Connection Menu..................................................................... 895 Connecting to the Payload Meter..................................................... 896 Configure the Payload Meter......................................................... 896 Setting the Date and Time........................................................... 896 Setting the Truck Type.............................................................. 897 Setting the Gauge Display Units..................................................... 897 Setting the Frame Serial Number..................................................... 897 Setting the Truck Number............................................................ 897 Setting the Komatsu Distributor..................................................... 897 Setting the Komatsu Customer........................................................ 897 Clean Truck Tare.................................................................... 898 Inclinometer Calibration............................................................ 898 DATA ANALYSIS........................................................................... 899 Creating a Query.................................................................... 899 Sorting on Truck Unit Number........................................................ 899 Sorting on Truck Type............................................................... 899 Sorting on Date Range............................................................... 900 Sorting on Time Range............................................................... 900 Payload Detail Screen............................................................... 901 Creating Reports.................................................................... 901 Summary - one page report........................................................... 902 Detailed - multi-page report........................................................ 902 Creating Graphs..................................................................... 903 Exporting Data...................................................................... 903 CSV Export.......................................................................... 903 Compressed.......................................................................... 904 Importing Data...................................................................... 905 Deleting Haul Cycle Records......................................................... 905 Viewing Alarms...................................................................... 906 Deleting Alarm Records.............................................................. 906 TROUBLESHOOTING SECTION..................................................................... 907 TROUBLESHOOTING......................................................................... 907 Viewing Active Alarms............................................................... 907 Real-Time Data Display.............................................................. 907 Testing the Payload Lights.......................................................... 907 Creating Log Files of Inputs........................................................ 908 Daily Inspections................................................................... 908 Periodic Maintenance................................................................ 908 Abnormal Displays at Power-Up....................................................... 909 No Payload Display When Key Switch is Turned ON..................................... 910 No Display on Speedometer........................................................... 911 No Display on Operator Display...................................................... 911 No Communications With PC........................................................... 912 Load Lights Don’t Light During Loading.............................................. 913 Load Lights Remain ON............................................................... 914 Load Lights Remain ON During Dumping................................................ 914 Display Doesn't Clear When The Load Is Dumped....................................... 914 Calibration Problems................................................................ 915 Alarm 1 - Left Front Pressure High.................................................. 916 Alarm 2 - Left Front Pressure Low................................................... 916 Troubleshoot Wiring to Left Front Suspension........................................ 916 Alarm 3 - Right Front Pressure High................................................. 917 Alarm 4 - Right Front Pressure Low.................................................. 917 Troubleshoot Wiring to Right Front Suspension....................................... 917 Alarm 5 -Left Rear Pressure High.................................................... 918 Alarm 6 - Left Rear Pressure Low.................................................... 918 Troubleshoot Wiring to Left Rear Suspension......................................... 918 Alarm 7 - Right Rear Pressure High.................................................. 919 Alarm 8 - Right Rear Pressure Low................................................... 919 Troubleshoot Wiring to Right Rear Suspension........................................ 919 Alarm 9 - Inclinometer High......................................................... 920 Alarm 10 - Inclinometer Low......................................................... 920 Troubleshoot Inclinometer Wiring.................................................... 920 Alarm 13 - Body Up Input Failure.................................................... 921 Alarm 16 - Memory Write Failure..................................................... 922 Alarm 17 - Memory Read Failure...................................................... 922 Alarm 18............................................................................ 923 Alarm 19............................................................................ 923 Alarm 22............................................................................ 923 Operator Switch Doesn't Work........................................................ 924 Alarm 26 - User Switch Fault - SELECT............................................... 924 Alarm 27 - User Switch Fault - SET.................................................. 924 Connector Map....................................................................... 925 Connectors.......................................................................... 926 PLMIII CHECK OUT PROCEDURE.................................................................. 927 General Description..................................................................... 927 Tools Required.......................................................................... 927 Checkout Procedure...................................................................... 927 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................. 931 Flashburn Programming............................................................... 931 Confirmation Checklist.............................................................. 933 RESERVE ENGINE OIL SYSTEM ...................................................................... 935 RESERVE ENGINE OIL SYSTEM................................................................... 937 Operation............................................................................... 938 LED Monitor Light....................................................................... 938 Tank Fill Control (Optional)............................................................ 939 Filling Procedure (Remote Fill Feature)................................................. 939 SERVICE................................................................................. 940 Every 10 Hours, or once each shift:................................................. 940 Every 500 Hours..................................................................... 940 Changing Oil........................................................................ 940 TROUBLESHOOTING......................................................................... 941 Circuit Fuse........................................................................ 941 SYSTEM ELECTRICAL SCHEMATICS............................................................ 942 SECTION N OPERATOR CAB ............................................................................. 943 TRUCK CAB AND COMPONENTS........................................................................ 945 TRUCK CAB AND COMPONENTS.................................................................... 947 TRUCK CAB............................................................................... 947 Description......................................................................... 947 Removal............................................................................. 948 Installation........................................................................ 949 CAB DOOR................................................................................ 950 Removal............................................................................. 950 Installation........................................................................ 950 Door Adjustment..................................................................... 950 Door Jamb Bolt Adjustment........................................................... 951 Door Handle Plunger Adjustment...................................................... 952 Replace Door Glass.................................................................. 953 Replace Door Window Regulator....................................................... 957 Replacing the Door Handle or Latch Assembly......................................... 958 Replacing the Door and Door Hinge Seal.............................................. 958 Removing the Door Opening Seal...................................................... 959 Installation........................................................................ 959 GLASS REPLACEMENT....................................................................... 960 Adhesive-bonded Windows............................................................. 960 Replacement Procedure............................................................... 960 WINDSHIELD & REAR GLASS................................................................. 962 Removal............................................................................. 962 Installation........................................................................ 962 CAB COMPONENTS ................................................................................. 965 CAB COMPONENTS.............................................................................. 967 WINDSHIELD WIPERS....................................................................... 967 WIPER MOTOR......................................................................... 967 Removal......................................................................... 967 Installation.................................................................... 967 WIPER ARM........................................................................... 967 Removal......................................................................... 967 Installation.................................................................... 968 WIPER LINKAGE....................................................................... 968 Removal......................................................................... 968 Installation.................................................................... 968 WINDSHIELD WASHER....................................................................... 969 Operation........................................................................... 969 Service............................................................................. 969 OPERATOR SEAT........................................................................... 970 Seat Belts.......................................................................... 970 Adjustment.......................................................................... 970 Inspection.......................................................................... 971 Removal............................................................................. 971 Installation........................................................................ 971 PASSENGER SEAT.......................................................................... 972 Inspection.......................................................................... 972 Removal............................................................................. 972 Installation........................................................................ 972 OPERATOR COMFORT................................................................................ 973 OPERATOR COMFORT............................................................................ 975 HEATER / AIR CONDITIONER................................................................ 975 Operation........................................................................... 975 Fan Control Knob.................................................................... 975 Temperature Control Knob............................................................ 975 Directional Control Knob............................................................ 975 Heater Vents........................................................................ 975 COMPONENTS.............................................................................. 976 Circuit Breakers.................................................................... 976 Relays.............................................................................. 976 Heater Core......................................................................... 976 Fan Motor And Speed Control......................................................... 977 Actuators........................................................................... 977 Cab Air Filter...................................................................... 977 ENVIRONMENTAL IMPACT OF AIR CONDITIONING................................................ 980 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................... 980 PRINCIPLES OF REFRIGERATION............................................................. 980 Air Conditioning.................................................................... 980 Refrigeration - The Act Of Cooling.................................................. 981 The Refrigeration Cycle............................................................. 981 AIR CONDITIONER SYSTEM COMPONENTS....................................................... 982 Compressor (Refrigerant Pump)....................................................... 982 Service Valves...................................................................... 982 Condenser........................................................................... 982 Receiver-Drier...................................................................... 982 Expansion Block Valve............................................................... 983 Accumulator......................................................................... 983 Evaporator.......................................................................... 983 ELECTRICAL CIRCUIT...................................................................... 984 Thermostat.......................................................................... 984 Compressor Clutch................................................................... 984 Trinary™ Switch..................................................................... 985 SYSTEM SERVICING........................................................................ 986 SERVICE TOOLS AND EQUIPMENT............................................................. 987 Recovery/Recycle Station............................................................ 987 Leak Detector....................................................................... 987 Service Valves...................................................................... 988 Vacuum Pump......................................................................... 988 Manifold Gauge Set.................................................................. 989 Installing Manifold Gauge Set....................................................... 990 Purging Air From Service Hoses...................................................... 990 SYSTEM PERFORMANCE TEST................................................................. 991 SYSTEM OIL.............................................................................. 992 Handling and Reusing PAG Oil........................................................ 992 Oil Quantity........................................................................ 992 Checking System Oil................................................................. 992 REFRIGERANT............................................................................. 993 Recycled Refrigerant................................................................ 993 Reclaimed Refrigerant............................................................... 993 Refrigerant Quantity................................................................ 993 R-134a Refrigerant Containers....................................................... 994 SYSTEM LEAK TESTING..................................................................... 994 Electronic Leak Detector............................................................ 995 Tracer Dyes......................................................................... 995 Soap and Water...................................................................... 995 RECOVERING AND RECYCLING THE REFRIGERANT................................................ 995 Performing the Recovery Cycle....................................................... 995 Performing the Recycling Procedure.................................................. 996 Evacuating and Charging the A/C System.............................................. 996 SYSTEM REPAIR........................................................................... 996 System Flushing..................................................................... 997 A/C DRIVE BELT CHECKOUT PROCEDURE....................................................... 998 Pulley Alignment.................................................................... 998 Belt Tension Check.................................................................. 998 COMPONENT REPLACEMENT...................................................................1000 Hoses and Fittings..................................................................1000 Lines...............................................................................1000 Expansion Valve.....................................................................1000 Receiver-Drier......................................................................1000 Thermostat..........................................................................1000 Compressor..........................................................................1001 Accumulator.........................................................................1001 Clutch..............................................................................1001 Servicing the Compressor Clutch.....................................................1002 Pulley Removal......................................................................1004 Clutch Coil Check...................................................................1005 Pulley Installation.................................................................1005 Clutch Assembly Installation........................................................1005 EVACUATING THE SYSTEM...................................................................1007 CHARGING THE A/C SYSTEM.................................................................1009 TROUBLESHOOTING.........................................................................1010 Preliminary Checks..................................................................1010 Diagnosis Of Gauge Readings And System Performance..................................1010 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS..........................................1011 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..........................................1017 OPERATOR CAB CONTROLS...........................................................................1019 OPERATOR CAB AND CONTROLS...................................................................1021 STEERING WHEEL AND CONTROLS.............................................................1022 Horn Button.........................................................................1022 Tilt / Telescope Lever..............................................................1022 Multi-Function Turn Signal Switch...................................................1022 STEERING COLUMN.........................................................................1023 Removal.............................................................................1023 Steering Column Inspection..........................................................1023 Installation........................................................................1023 STEERING WHEEL..........................................................................1024 Removal.............................................................................1024 Installation........................................................................1024 PEDALS..................................................................................1026 Service Brake Pedal.................................................................1026 Dynamic Retarding...................................................................1026 Dynamic Retard Pedal................................................................1026 Throttle/Accelerator Pedal..........................................................1026 GRADE/SPEED RETARD CHART................................................................1027 OVERHEAD PANEL AND DISPLAYS.............................................................1028 CENTER CONSOLE..........................................................................1029 Directional Control Lever...........................................................1029 Override/Fault Reset Switch.........................................................1030 Engine Stop Switch..................................................................1030 L.H. Window Control Switch..........................................................1030 R.H. Window Control Switch..........................................................1030 Hoist Control Lever.................................................................1030 Raising The Dump Body...............................................................1030 Lowering The Dump Body..............................................................1030 Retard Speed Control (RSC) Adjust Dial..............................................1031 Retard Speed Control (RSC) Switch...................................................1031 Data Store Button...................................................................1032 KOMTRAX Plus Snapshot In Progress Light.............................................1032 Link Energized Light................................................................1032 Service Engine Light................................................................1032 DIAGNOSTIC PORTS....................................................................1032 KOMTRAX Plus Diagnostic Port........................................................1032 Interface Module (IM) Diagnostic Port...............................................1032 Payload Meter Diagnostic Port.......................................................1032 Truck Control Interface (TCI) Diagnostic Port.......................................1032 Propulsion System Controller (PSC) Diagnostic Port..................................1032 Engine Diagnostic Port (CENSE)......................................................1032 Engine Diagnostic Port (QUANTUM)....................................................1032 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.......................................1033 Fan Control Knob....................................................................1033 Temperature Control Knob............................................................1033 Directional Control Knob............................................................1033 Heater Vents........................................................................1033 INSTRUMENT PANEL........................................................................1034 Key Switch..........................................................................1036 Starting............................................................................1036 Engine Stop Switch with Five Minute Idle Timer Delay................................1036 Rotating Beacon Light Switch (Optional).............................................1037 Heated Mirror Switch (Optional).....................................................1037 Rest Switch.........................................................................1037 Wheel Brake Lock Control............................................................1037 Hazard Warning Lights...............................................................1037 Cab/Air Conditioner Vents...........................................................1037 Engine Oil Pressure Gauge...........................................................1038 Right Turn Signal Indicator.........................................................1038 Tachometer..........................................................................1038 High Beam Indicator.................................................................1038 Speedometer/Payload Meter Display...................................................1038 Left Turn Signal Indicator..........................................................1038 Water Temperature Gauge.............................................................1038 Lamp Test Switch....................................................................1038 Light Switch........................................................................1038 Ladder Light Switch.................................................................1039 Manual Backup Switch................................................................1039 Fog Lights (Optional)...............................................................1039 Payload Meter Switch................................................................1039 Panel Light Dimmer..................................................................1039 Hydraulic Oil Temperature Gauge.....................................................1040 Hourmeter...........................................................................1040 Fuel Level Gauge....................................................................1040 OVERHEAD STATUS / WARNING INDICATORS....................................................1041 Status / Warning Indicator Light Symbols............................................1042 KOMTRAX Plus MONITORING SYSTEM..........................................................1048 Operation...........................................................................1048 Interface Module....................................................................1049 Basic Precautions...................................................................1049 SECTION P LUBRICATION AND SERVICE ..................................................................1051 LUBRICATION AND SERVICE.........................................................................1053 LUBRICATION AND SERVICE.....................................................................1055 GENERAL.................................................................................1055 830E SERVICE CAPACITIES.................................................................1055 HYDRAULIC TANK SERVICE..................................................................1055 Adding Oil..........................................................................1055 COOLING SYSTEM SERVICE..................................................................1056 Radiator Filling Procedure..........................................................1056 Coolant Specifications..............................................................1056 Unacceptable Practices..............................................................1056 WHEEL MOTOR SERVICE.....................................................................1056 RESERVE ENGINE OIL SYSTEM (Optional)....................................................1057 Reserve Oil Tank Filling Procedure (Remote fill)....................................1057 Inline Screen.......................................................................1057 QUICK FILL SERVICE CENTER...............................................................1058 LUBRICATION CHART.......................................................................1059 10 HOUR (DAILY) INSPECTION..............................................................1060 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................1063 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................1064 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1065 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1069 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS...........................................1071 2500 HOUR MAINTENANCE CHECKS............................................................1072 5000 HOUR MAINTENANCE CHECKS............................................................1072 AUTOMATIC LUBRICATION SYSTEM ...................................................................1073 AUTOMATIC LUBRICATION SYSTEM................................................................1075 GENERAL DESCRIPTION.....................................................................1075 SYSTEM COMPONENTS.......................................................................1077 Filter..............................................................................1077 Hydraulic Motor and Pump............................................................1077 Grease Reservoir....................................................................1077 Pressure Reducing Valve.............................................................1077 Flow Control Valve..................................................................1077 Solenoid Valve......................................................................1077 Vent Valve..........................................................................1077 Lubrication Cycle Timer.............................................................1077 Over Pressure Cut Off Switch........................................................1077 Grease Pressure Failure Switch......................................................1077 Injectors...........................................................................1077 Relief Valve........................................................................1077 SYSTEM OPERATION........................................................................1078 GENERAL INSTRUCTIONS....................................................................1079 Required Lubricant..................................................................1079 System Priming......................................................................1079 Filter Assembly.....................................................................1079 LUBRICANT PUMP..........................................................................1080 Pump Housing Oil Level..............................................................1080 Pump Pressure Control...............................................................1080 INJECTORS (SL-1 Series “H”).............................................................1080 Injector Specifications.............................................................1080 Injector Adjustment.................................................................1080 INJECTOR OPERATION......................................................................1082 PREVENTIVE MAINTENANCE PROCEDURES.......................................................1083 Daily Lubrication System Inspection.................................................1083 250 Hour Inspection.................................................................1083 1,000 Hour Inspection...............................................................1083 SYSTEM CHECKOUT.........................................................................1084 Lubrication Controller Check........................................................1084 Lubrication Controller Operation....................................................1084 Lubrication Controller Components...................................................1084 Lubrication Controller Adjustment...................................................1084 SYSTEM TROUBLESHOOTING CHART............................................................1086 SECTION Q ALPHABETICAL INDEX .......................................................................1089 SECTION R SYSTEM SCHEMATICS ........................................................................1093 HH360 HYDRAULIC SCHEMATIC ......................................................................1095 HH361 HYDRAULIC SCHEMATIC ......................................................................1096 HE484 ELECTRICAL SCHEMATIC HEATER/AC CONTROLS ..................................................1098 XS3200 ELECTRICAL SCHEMATIC ....................................................................1099 XS3201-1....................................................................................1099 XS3202-4....................................................................................1100 XS3203-3....................................................................................1101 XS3204-1....................................................................................1102 XS3205-2....................................................................................1103 XS3206-2....................................................................................1104 XS3207-3....................................................................................1105 XS3208-2....................................................................................1106 XS3209-2....................................................................................1107 XS3210-3....................................................................................1108 XS3211-4 ...................................................................................1109 XS3212-3....................................................................................1110 XS3213-3....................................................................................1111 XS3214-4....................................................................................1112 XS3215-2....................................................................................1113 XS3216-3....................................................................................1114 XS3217-2....................................................................................1115 XS3218-1....................................................................................1116 XS3219-2....................................................................................1117 XS3220-4....................................................................................1118 XS3221-2....................................................................................1119 XS3222-3 ...................................................................................1120 XS3223-1....................................................................................1121 XS3224-1....................................................................................1122 XS3225-3....................................................................................1123 XS3226-2....................................................................................1124 XS3227-3....................................................................................1125 XS3228-3....................................................................................1126 XS3229-2....................................................................................1127 XS3230-2....................................................................................1128 XS3231-2....................................................................................1129 XS3232-3....................................................................................1130 XS3233-2....................................................................................1131 XS3234-3....................................................................................1132 XS3235-3....................................................................................1133 XS3236-0....................................................................................1134
KOMATSU 830E-AC DUMP TRUCK SHOP MANUAL A30001-A30035 – PDF DOWNLOAD:
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