KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30710 – A30732 With Full Time Axle Blower) – PDF DOWNLOAD

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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30710 – A30732 With Full Time Axle Blower)

KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30710 – A30732 WITH FULL TIME AXLE BLOWER) – PDF DOWNLOAD:

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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30710 – A30732 With Full Time Axle Blower)

• 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 U.S. standard and metric (SI) 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 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system.
• The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.

TABLE OF CONTENTS:

KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30710 – A30732 With Full Time Axle Blower)

MAIN MENU........................................................................  0
COVER............................................................................  1
FOREWORD.........................................................................  3
CONTENTS.........................................................................  5
GENERAL INFORMATION..............................................................  7
	Truck Component Description and Specifications...............................  9
	General Safety and Truck Operation........................................... 13
		Precautions During Operation............................................. 17
		Battery.................................................................. 22
		Precautions For Maintenance.............................................. 23
		During Maintenance....................................................... 24
		Tires.................................................................... 27
		Additional Job Site Rules................................................ 28
		When Repairs Are Necessary............................................... 29
		Operating Instructions................................................... 30
	Warnings and Cautions........................................................ 43
	Charts and Tables............................................................ 51
	Storage Procedures........................................................... 57
		Short Term Idle Periods.................................................. 59
		Preparation for Storage.................................................. 60
		Removal from Storage..................................................... 61
		Reconditioning an Idle Vehicle........................................... 63
		Engine Operation......................................................... 65
		After Engine Has Started................................................. 66
		Engine Storage-Cummins................................................... 67
			Engine Storage (Short Term).......................................... 67
			Engine Storage (Long Term)........................................... 68
		Electric Drive Trucks.................................................... 69
		Preservation and Storage- Allison Transmission........................... 73
STRUCTURES....................................................................... 75
	Structural Components........................................................ 77
		Ladders.................................................................. 77
		Right Hand Deck.......................................................... 78
			Removal.............................................................. 78
			Installation......................................................... 78
		Center and Left Hand Deck Components..................................... 79
		Fuel Tank................................................................ 80
			Removal.............................................................. 80
			Installation......................................................... 80
	Dump Body.................................................................... 81
		Removal.................................................................. 81
		Installation............................................................. 82
		Body Pads................................................................ 83
			Adjustment........................................................... 84
		Body Guide............................................................... 84
		Body-Up Retention Cable.................................................. 84
		Body Position Indicator.................................................. 85
		Rock Ejectors............................................................ 85
			Inspection........................................................... 85
		Hoist Limit Switch....................................................... 85
		Body Up Switch........................................................... 85
ENGINE........................................................................... 87
	Power Module................................................................. 89
		Preparation.............................................................. 89
			Removal.............................................................. 89
			Installation......................................................... 89
	Cooling System............................................................... 95
		Cooling System Description............................................... 95
		Radiator................................................................. 96
			Removal.............................................................. 96
			Installation......................................................... 98
		Radiator Filling Procedure............................................... 98
	Power Train.................................................................. 99
		Alternator Removal Procedure............................................. 99
			Engine Alternator Mating.............................................101
			Measuring Procedure..................................................101
			Joining Alternator and Engine........................................103
		Engine...................................................................104
			Removal..............................................................104
			Installation.........................................................104
	Air Filtration System........................................................105
		Air Cleaner..............................................................105
			Operation............................................................105
			General Service Information..........................................105
		Main Filter Element......................................................105
		Safety Filter Element....................................................107
			Air Intake Troubleshooting...........................................107
		Air Cleaner Assembly Cleaning............................................107
			Main Filter Cleaning.................................................107
			Precleaner Section Cleaning..........................................108
	Fan Clutch...................................................................111
		REMOVAL & INSTALLATION TOOLING...........................................111
		FAN CLUTCH - DISASSEMBLY.................................................114
		CLEANING AND INSPECTION..................................................124
		ASSEMBLY - FAN CLUTCH....................................................128
		TEST PROCEDURE...........................................................142
ELECTRICAL SYSTEM (24VDC NON-PROPULSION).........................................143
	24VDC Electric Supply System.................................................145
		Electrical System Description............................................  0
		Battery- Maintenance and Service.........................................145
			Troubleshooting......................................................145
		Battery Charging System (Niehoff)........................................147
			General Description..................................................147
			Troubleshooting Procedures...........................................147
			On Vehicle Troubleshooting Guide- Self Energized Alternator..........150
			Advanced System Troubleshooting......................................152
		24VDC Electric Starter System (with Prelube).............................154
			Operation............................................................154
			Maintenance..........................................................155
			Troubleshooting......................................................156
	24VDC Electrical System Components...........................................167
		Passenger Seat Base Compartment..........................................167
		Components...............................................................167
		Alarm Indicating Device..................................................170
		Battery Equalizer........................................................172
		Body-Up Switch...........................................................173
		Hoist Limit Switch.......................................................173
		24Volt Relay and Diode Boards............................................174
		Circuit Breaker Chart....................................................180
	VEHICLE HEALTH MONITORING SYSTEM (VHMS)......................................181
		VHMS BASIC FEATURES......................................................181
			Gather Data..........................................................181
			Convert and Record Data..............................................182
			Communicate Data to Off-Board Systems................................182
		USING THE VHMS SYSTEM....................................................183
			Turning the VHMS System ON...........................................183
			Normal VHMS Operation................................................184
			Turning the VHMS System OFF..........................................184
			Downloading from the VHMS controller.................................184
		VHMS DATA ITEMS..........................................................185
			Fault Codes..........................................................185
			Machine History......................................................185
			VHMS History.........................................................185
			Snapshots............................................................185
			Manual Snapshots.....................................................187
			Trends...............................................................187
			Histogram (Load Map) Data............................................189
			Haul Cycle Data......................................................189
			Alarm and Snapshot Triggers..........................................191
			Satellite Features...................................................193
		VHMS DIAGNOSTIC FEATURES.................................................193
			Fault History........................................................193
			VHMS LED Digits......................................................193
		VHMS COMPONENTS..........................................................194
			VHMS Controller......................................................194
			Removal..............................................................194
			Installation.........................................................195
			OrbComm Controller...................................................195
			Removal..............................................................195
			Installation.........................................................196
			Interface Module.....................................................196
			Removal..............................................................197
			Installation.........................................................197
			Temperature Sensors..................................................198
			Pressure Sensors.....................................................199
	VHMS SOFTWARE................................................................201
		NECESSARY SOFTWARE.......................................................201
		NECESSARY TOOLS..........................................................201
		VHMS TOOL BOX INSTALLATION...............................................202
		VHMS SETTING TOOL INSTALLATION...........................................202
		VHMS INITIALIZATION PROCEDURE............................................202
			Preliminary Checks...................................................202
			Initialization Steps.................................................203
			Select Operation.....................................................203
			VHMS Setting Function................................................203
			Machine Information Setting(1).......................................203
			Machine Information Setting(2).......................................203
			Date & Time Setting..................................................204
			GCC Setting..........................................................204
			Setting Summary......................................................204
		VHMS SNAPSHOT PROCEDURE..................................................205
		VHMS DOWNLOAD............................................................205
		VHMS FTP UPLOAD..........................................................206
		LOCATION OF DOWNLOAD FILES...............................................207
		INSTALLING FLASHBURN PROGRAM.............................................208
		INSTALLING APPLICATION CODE INTO INTERFACE MODULE........................208
		INSTALLING VHMS WATCHER PROGRAM..........................................209
		INSTALLING VHMS WATCHER DATA FILES.......................................209
		WHEN REPLACING A VHMS CONTROLLER.........................................209
			To Set: Date & Time; Satellite; Payload Meter........................212
			Review Setting Information...........................................213
	VHMS CHECKOUT & TROUBLESHOOTING..............................................215
		VHMS CHECKOUT PROCEDURE..................................................215
			General..............................................................215
			Structure and Purpose................................................216
			Necessary Equipment:.................................................216
		VHMS SYSTEM CHECKOUT.....................................................216
			Preliminary..........................................................216
			Checking Inputs To The Interface Module..............................217
			Checking Outputs From The Interface Module...........................220
		VHMS CONTROLLER CHECKOUT.................................................220
		TROUBLESHOOTING..........................................................221
			Communications Networks..............................................221
			Coaxial Cable........................................................221
		VHMS COMPONENTS..........................................................222
			VHMS Controller......................................................222
			OrbComm Controller...................................................223
			Interface Module.....................................................223
		FAULT CODES..............................................................224
			Fault History........................................................224
			VHMS LED Display Fault Codes.........................................225
			Chassis Fault Codes..................................................226
			Engine Fault Codes...................................................229
		FAULT TREE ANALYSIS......................................................235
			Unable to connect to VHMS from laptop PC.............................235
			Flashing Error Code N4-23 (PLM III Communications Fault).............236
			Flashing Error Code N4-22 (Engine Communications Fault)..............237
			No Data Received By WebCARE..........................................238
			Coaxial Cable Troubleshooting........................................239
	VHMS FORMS...................................................................241
		VHMS INITIALIZATION CHECK LIST...........................................241
		VHMS DATA DOWNLOAD.......................................................242
		VHMS INITIALIZATION FORM.................................................242
		VHMS INITIALIZATION CHECK LIST...........................................243
		VHMS INITIALIZATION FORM.................................................245
ELECTRICAL PROPULSION COMPONENTS.................................................247
	Electrical Propulsion Components.............................................249
		General System Description...............................................249
		Control System...........................................................249
		FL275 Panel..............................................................251
			Card Replacement.....................................................252
			Card Repair..........................................................252
			Computer Description.................................................253
			Software.............................................................253
		2-Digit Display Panel....................................................256
			Events...............................................................256
			Frames...............................................................257
			Windows..............................................................257
			2 Digit Display Panel Codes (Table I)................................259
			Subcode Descriptions (Table II)......................................266
		Portable Test Unit (PTU).................................................269
			Description..........................................................269
			Software Installation Preparation....................................270
				The Main Menu....................................................272
				PTU Software Menu Tree...........................................273
				Configuration (CFG) File Conversion..............................274
			Statex Configuration Files...........................................278
			Programming The Truck................................................289
				PTU Hookup.......................................................289
				Download Configuration Files.....................................291
			Event Data...........................................................293
			Statistical Data.....................................................295
			Statistical Data Codes- Counters (Table III).........................297
			Statistical Data Codes- Profiles (Table IV)..........................302
			Truck Specific Information...........................................306
			Temporary Truck Settings.............................................307
			Miscellaneous Software Features......................................308
				Saving Data......................................................308
				PTU Abbreviations................................................309
				Other Menu Selections............................................309
		Miscellaneous Electrical Propulsion Components...........................310
			Alternator...........................................................310
			Electric Wheel Motors................................................310
			Electronic Accelerator and Retard Control............................310
			Cooling Blower Warning System........................................312
			Electrical Control Cabinet...........................................313
		Statex III Electric Drive Components Abbreviations.......................318
	Statex III Electrical System Checkout Procedure..............................321
		General Information......................................................323
		Communications Port Check................................................324
			PTU Hookup...........................................................324
		1.0 Sequence Tests.......................................................326
			Throttle System Check and Adjustment.................................327
				Electronic Throttle System.......................................327
				Electronic Throttle System fuel Enhancement ("Fuel Saver").......328
			Retard System Check and Adjustment- Electronic Pedal System..........330
				Williams Electronic Retard Pedal and ACC/RET or RET Interface....330
				Electronic Retard Pedal, Current Production Trucks...............331
			Reverser and Propulsion Contractors Check............................333
			Propulsion Lockout Test (DDEC&MTU Engine Trucks Only)................334
			Retard Contractors Operation Check...................................335
			Ground Fault Sensing Check...........................................335
			Ground Fault in Retard Operation Check...............................335
			Override Operation Check.............................................336
			Anti-Reversal Function (AR) Check....................................337
			Overspeed Retard Operation Check.....................................337
			Hoist Interlock Operation Check......................................338
			Motor Blower Fault Light Operation Check.............................339
		Digital Input/Output Signals Tests- FL275 Card Panel.....................340
			Setup Manual Digital Input/Output Test on PTU........................340
			Digital Input Checks.................................................341
			Digital Output Checks................................................343
		Analog Input Signals Test- FL275 Card Panel..............................346
			Setup Analog Input Monitor Screen on PTU.............................346
			Analog Input Checks..................................................347
			Frequency Input Checks...............................................354
		Speed Event Checks.......................................................356
			Single Speed Overspeed-Overspeed Settings Check......................357
			Empty Truck- 2 Speed Overspeed Settings Check........................357
			Loaded Truck- 2 Speed Overspeed Settings Check.......................357
			Other Speed Events Checks............................................357
		Retard Speed Control System Check........................................359
			Overspeed Pickup and Dropout Check...................................359
			Retard Pot Maximum Setting Check.....................................360
			Retard Pot Minimum Setting Check.....................................360
			Accelerator Pedal Override of Retard Speed Control...................360
		Load Test Using Truck Retard Grids.......................................361
			Load Test............................................................362
		Motor Field current Check in Retarding...................................363
			Retard Check.........................................................363
		Miscellaneous Component Test and Adjustment..............................364
			Brake System Interlocks Check........................................364
			Blower Loss Pressure Switch Adjustment...............................365
			SYNC Transformer Checkout............................................365
			Power Contactor Position Sensor Adjustment...........................365
			Battery Boost Adjustment.............................................366
			Isolation Amplifier& Voltage Module Test.............................366
				Voltage Measuring Module Test (VMM1&VMM2)........................366
				ISO-AMP Test.....................................................366
			Motor Rotation Test..................................................367
			Ground Fault Checks..................................................368
		Miscellaneous Charts.....................................................369
			Wheel Motor Gear Ratios..............................................369
			Maximum Allowable Truck Speeds.......................................370
			Engine Options.......................................................371
DRIVE AXLE, SPINDLE AND WHEELS...................................................373
	Tires and Rims...............................................................375
		Front Tires and Rims.....................................................375
			Removal..............................................................375
			Installation.........................................................376
		Rear Tires and Rims......................................................377
			Removal..............................................................377
			Installation.........................................................378
		Rim......................................................................379
			Tire Removal.........................................................379
			Rim and Tire Preparation.............................................379
			Lubricants...........................................................380
			Tire Installation....................................................380
	Front Wheel Hub and Spindle..................................................383
		Wheel Hub and Spindle Assembly...........................................383
			Removal..............................................................383
			Spindle Pusher Tool Usage............................................384
			Installation.........................................................385
			Disassembly..........................................................387
			Cleaning and Inspection..............................................387
			Assembly.............................................................388
			Wheel Bearing Adjustment.............................................390
			Wheel Bearing Adjustment (Tire Mounted)..............................390
		Steering Cylinders and Tie Rod...........................................392
			Spherical Bearing Wear Limits........................................392
			Removal..............................................................393
			Installation.........................................................393
			Bearing Replacement..................................................393
		Toe-In Adjustment........................................................395
	Rear Axle Housing Attachment.................................................397
		Pivot Pin................................................................397
			Removal..............................................................397
			Installation.........................................................397
		Pivot Eye Bearing........................................................398
			Disassembly..........................................................398
			Assembly.............................................................398
		Pivot Eye Repair.........................................................399
			Removal..............................................................399
			Disassembly..........................................................399
			Assembly.............................................................399
			Installation.........................................................399
		Anti-Sway Bar............................................................400
			Removal..............................................................400
			Installation.........................................................400
			Disassembly..........................................................400
			Cleaning and Inspection..............................................400
			Assembly.............................................................400
	Rear Axle Housing............................................................401
		Rear Axle Housing........................................................401
			Removal..............................................................401
			Installation.........................................................401
		Wheel Motor..............................................................401
			Removal..............................................................401
			Cleaning and Inspection..............................................402
			Installation.........................................................402
HYDRAIR II SUSPENSIONS...........................................................403
	Front Suspension.............................................................405
		Removal..................................................................405
		Installation.............................................................406
			"Turn of the Nut" Tightening Procedure...............................408
		Minor Repair.............................................................409
			Bearing Structure Removal............................................409
			Bearing Structure Installation.......................................409
		Major Suspension Rebuild.................................................410
			Disassembly..........................................................410
			Assembly.............................................................411
			Pressure Test........................................................412
	Rear Suspension..............................................................413
		Removal..................................................................413
		Installation.............................................................415
		Disassembly..............................................................417
		Cleaning and Inspection..................................................417
		Assembly.................................................................417
		Pressure Test............................................................418
	Oiling and Charging Procedure................................................419
		General..................................................................419
		Equipment List...........................................................419
		Front Suspension.........................................................421
			Front Suspension Oiling..............................................421
			Front Suspension Nitrogen Charging...................................422
		Rear Suspension..........................................................423
			Rear Suspension Oiling...............................................423
			Rear Suspension Nitrogen Charging....................................424
		Oil and Nitrogen Specifications Chart....................................426
BRAKE CIRCUIT....................................................................427
	Brake Circuit................................................................429
		Service Brake Circuit Operation..........................................429
		Secondary Braking and Automatic Apply....................................430
		Parking Brake Circuit....................................................430
		Brake Lock Circuit.......................................................432
		Warning Circuit..........................................................432
	Brake Circuit Component Service..............................................435
		Brake Valve..............................................................435
			Removal..............................................................435
			Installation.........................................................437
			Disassembly..........................................................438
			Cleaning and Inspection..............................................440
			Assembly.............................................................440
		Differential Pressure Switch.............................................443
			Disassembly..........................................................443
			Cleaning and Inspection..............................................443
			Assembly.............................................................443
		Valve Bench Test and Adjustment..........................................444
			Test Set Up Procedure................................................445
			Differential Pressure Switch Test....................................445
			Final Test and Adjustment............................................446
		Installation of Brake Pedal Actuator Assembly to Brake Valve.............447
		Brake Valves with Integral Mounted Electronic Retard Pedal...............448
		Hydraulic Brake Accumulators.............................................449
			Removal..............................................................449
			Installation.........................................................449
			Disassembly..........................................................449
			Cleaning and Inspection..............................................450
			Assembly.............................................................451
	Brake Circuit Check-Out Procedure............................................455
		Equipment Required.......................................................458
		Initial System Set-Up....................................................459
		Parking Brake............................................................459
		Brake System Check-Out...................................................459
		Failure Modes Check-Out..................................................460
		Brake Circuit and Brake Valve Troubleshooting............................462
		Hydraulic Brake System Check-Out Procedure Data Sheet....................465
	Rockwell Wheel Speed Front Disc Brakes.......................................467
		Brake Caliper............................................................467
		Brake Lining.............................................................471
		Front Service Brake Conditioning (Burnishing) Procedure..................472
		Brake Bleeding Procedures................................................473
	Rockwell Armature Speed Rear Disc Brakes.....................................475
		Rear Brakes..............................................................475
		Caliper, Disc and Parking Brake..........................................475
		Caliper Piston...........................................................480
		Bench Test...............................................................486
		Brake Lining.............................................................487
		Service Brake Conditioning (Burnishing) Procedure........................490
		Brake Bleeding Procedure.................................................492
	Rockwell Disc Parking Brake..................................................493
		Park Brake Caliper.......................................................493
			Removal..............................................................493
			Installation.........................................................494
			Parking Brake Adjustment.............................................494
			Park Brake Caliper Disassembly.......................................496
			Cleaning and Inspection..............................................496
			Park Brake Caliper Assembly..........................................497
		Park Brake Lining Replacement............................................498
		Park Brake Burnish Procedure.............................................498
		Brake Bleeding Procedure.................................................498
HYDRAULIC SYSTEM.................................................................499
	Hydraulic System.............................................................501
		Hydraulic System Operation...............................................501
		Component Description....................................................502
		Axle Blower System.......................................................504
	Hydraulic System Component Repair............................................505
		Hoist Pump...............................................................505
		Brake / Steering Pump....................................................515
		Axle Blower Pump.........................................................529
		Hand Wheel Control.......................................................536
		Hydraulic Tank...........................................................538
			Hydraulic Tank Strainers.............................................539
	Steering Circuit.............................................................541
		Steering Circuit Operation...............................................541
		Component Description....................................................542
			Steering Pump Compensator Vent.......................................542
			Steering Depressurization Valve......................................543
			Pilot To Open Check Valve............................................543
			Pilot To Open Check Valve Control Solenoid...........................543
			Steering Control Unit................................................543
			Flow Amplifier.......................................................544
			Bleed Down Manifold..................................................554
			Accumulators.........................................................555
			High Pressure Filter.................................................555
			Brake/Steering Pump..................................................555
			Operation............................................................556
	Steering Circuit Component Repair............................................557
		Bleed Down Manifold......................................................557
		Accumulator..............................................................558
			Steering Accumulator Charging Procedure..............................562
		Flow Amplifier...........................................................563
		Steering Control Unit....................................................568
		Steering Cylinder........................................................574
		Steering Circuit Filter..................................................575
		Steering and Brake Pump..................................................576
	Hoist Circuit................................................................597
		Hoist Circuit Operation..................................................597
		Component Description....................................................599
			Hydraulic Tank.......................................................599
			Hoist Pump...........................................................599
			High Pressure Filters................................................599
			Hoist Valve..........................................................600
			Hoist Pilot Valve....................................................601
			Hoist Up Limit Solenoid..............................................601
			Pilot Operated Check Valve...........................................601
			Electronic Hoist Controller..........................................602
			Counterbalance Valve Manifold........................................603
		Hoist System Operation Modes.............................................604
	Hoist Circuit Component Repair...............................................615
		Hoist Valve..............................................................615
			Inlet Section........................................................616
			Spool Section........................................................618
		Hoist Pilot Valve........................................................621
		Body Up Limit Solenoid...................................................624
		Pilot Operated Check Valve...............................................624
		Hoist Controller.........................................................624
		Hoist Cylinders..........................................................625
		Counterbalance Manifold..................................................633
		Disabled Truck Dumping Procedure.........................................634
	Hydraulic Checkout Procedure.................................................635
		Initial Start Up and Flushing............................................636
		Component Checkout and Adjustment........................................637
		Brake/Steering Pump Pressure Procedure...................................638
			Steering Circuit Pressure Adjustment.................................638
			Remote Pressure Compensator Adjustment...............................638
		Axle Box Blower Circuit Adjustment.......................................640
		Adjustment Procedure for Hoist Counterbalance Cartridge Valve............643
			Counterbalance Valve Adjustment......................................644
			Manifold Reassembly..................................................644
		Hoist Controller Troubleshooting Procedure...............................645
		Troubleshooting Charts...................................................647
			Steering Circuit.....................................................647
			Brake/Steering Pump..................................................649
			Hoist Pump...........................................................651
			Flow Amplifier.......................................................653
OPTIONS AND SPECIAL TOOLS........................................................661
	Ansulfire Control System Manual..............................................663
		Operation................................................................663
		Inspection and Maintenance...............................................663
		Recharging Procedures....................................................664
	Wiggins Quick Fill Fuel System...............................................665
		Fuel Receiver............................................................665
		Tank Breather Valve......................................................666
	Buckeye Quick Fill Fuel System...............................................669
		Tank Breather Valve......................................................669
		Fuel Receiver............................................................670
	Engine Coolant Heater........................................................671
		Heating Element..........................................................671
		Thermostat...............................................................672
	Special Tools................................................................673
	Air Conditioning System......................................................679
		Environmental Impact.....................................................679
		Operator Cab Air Conditioning............................................680
		Principles of Refrigeration..............................................680
		Air Conditioner System Components........................................682
		Electrical Circuit.......................................................684
		System Servicing.........................................................686
		Service Tools and Equipment..............................................689
		Manifold Gauge Set.......................................................691
		System Performance Test..................................................694
		System Leak Testing......................................................695
		System Repair............................................................696
		Evacuating the System....................................................703
		Troubleshooting..........................................................705
		Preventive Maintenance Schedule for A/C Systems..........................713
	Radiator Shutters............................................................715
	PAYLOAD METER III ™..........................................................719
		INDEX....................................................................719
		OPERATION SECTION........................................................723
			Introduction.........................................................723
				Data Summary.....................................................723
				Data Gathering...................................................723
			COMPONENT DESCRIPTION................................................724
				System Diagram...................................................724
				Suspension Pressure Sensors......................................724
				Inclinometer.....................................................724
				Operator Display.................................................724
				Operator Switch..................................................725
				Speed Input......................................................725
				Body-Up Switch...................................................725
				Brake Lock Switch................................................725
				Payload Meter....................................................725
				Communications Ports.............................................725
				Keyswitch Input..................................................726
				Payload Meter Power..............................................726
				Load Lights......................................................726
				Wiring and Termination...........................................727
				TCI Outputs......................................................727
			OPERATOR’S DISPLAY AND SWITCH........................................728
				Reading the Speedometer..........................................728
				Reading the Load Display.........................................728
				Using the Operator ID............................................728
				Using the Load and Ton Counter...................................728
				Total Ton Counter................................................728
				Total Load Counter...............................................729
				Clearing the Counters............................................729
				Viewing Live Sensor Data.........................................729
				Other Display Messages...........................................729
			PAYLOAD OPERATION & CALCULATION......................................730
				Description of Haul Cycle States.................................730
				Haul Cycle Description...........................................730
				Load Calculation.................................................731
				Carry Back.......................................................731
				Measurement Accuracy.............................................731
			SOURCES FOR PAYLOAD ERROR............................................731
				Payload Error....................................................731
				Loading Conditions...............................................732
				Pressure Sensors.................................................732
				Swingloads.......................................................732
				Speed and Distance...............................................732
			HAUL CYCLE DATA......................................................732
				Haul Cycle Data..................................................733
				Haul Cycle Warning Flags.........................................734
				M: Haul Cycle Too Long...........................................735
				N: Sensor Input Error............................................735
				Frame Torque Data................................................735
				Sprung Weight Data...............................................735
				Maximum Speed Data...............................................735
				Alarm Records....................................................735
				Fault Code Data..................................................736
			PC SOFTWARE OVERVIEW.................................................737
				PC Overview......................................................737
				System Configuration.............................................737
				Installing the PLMIII Software...................................737
			DOWNLOADING DATA.....................................................738
			PLM III SYSTEM CONFIGURATION.........................................739
				Starting Communications..........................................739
				Displayed Payload Units..........................................739
				Time Units.......................................................739
				Connection Menu..................................................739
				Connecting to the Payload Meter..................................740
				Configure the Payload Meter......................................740
				Setting the Date and Time........................................740
				Setting the Truck Type...........................................741
				Setting the Gauge Display Units..................................741
				Setting the Frame Serial Number..................................741
				Setting the Truck Number.........................................741
				Setting the Komatsu Distributor..................................741
				Setting the Komatsu Customer.....................................741
				Clean Truck Tare.................................................742
				Inclinometer Calibration.........................................742
			DATA ANALYSIS........................................................743
				Creating a Query.................................................743
				Sorting on Truck Unit Number.....................................743
				Sorting on Truck Type............................................743
				Sorting on Date Range............................................744
				Sorting on Time Range............................................744
				Payload Detail Screen............................................745
				Creating Reports.................................................745
				Summary - one page report........................................746
				Detailed - multi-page report.....................................746
				Creating Graphs..................................................747
				Exporting Data...................................................747
				CSV Export.......................................................747
				Compressed.......................................................748
				Importing Data...................................................749
				Deleting Haul Cycle Records......................................749
				Viewing Alarms...................................................750
				Deleting Alarm Records...........................................750
		TROUBLESHOOTING SECTION..................................................751
			TROUBLESHOOTING......................................................751
				Viewing Active Alarms............................................751
				Real-Time Data Display...........................................751
				Testing the Payload Lights.......................................751
				Creating Log Files of Inputs.....................................752
				Daily Inspections................................................752
				Periodic Maintenance.............................................752
				Abnormal Displays at Power-Up....................................753
				No Payload Display When Keyswitch is Turned ON...................754
				No Display on Speedometer........................................755
				No Display on Operator Display...................................755
				No Communications With PC........................................756
				Load Lights Don’t Light During Loading...........................757
				Load Lights Remain ON............................................758
				Load Lights Remain ON During Dumping.............................758
				Display Doesn't Clear When The Load Is Dumped....................758
				Calibration Problems.............................................759
				Alarm 1 - Left Front Pressure High...............................760
				Alarm 2 - Left Front Pressure Low................................760
				Troubleshoot Wiring to Left Front Suspension.....................760
				Alarm 3 - Right Front Pressure High..............................761
				Alarm 4 - Right Front Pressure Low...............................761
				Troubleshoot Wiring to Right Front Suspension....................761
				Alarm 5 -Left Rear Pressure High.................................762
				Alarm 6 - Left Rear Pressure Low.................................762
				Troubleshoot Wiring to Left Rear Suspension......................762
				Alarm 7 - Right Rear Pressure High...............................763
				Alarm 8 - Right Rear Pressure Low................................763
				Troubleshoot Wiring to Right Rear Suspension.....................763
				Alarm 9 - Inclinometer High......................................764
				Alarm 10 - Inclinometer Low......................................764
				Troubleshoot Inclinometer Wiring.................................764
				Alarm 13 - Body Up Input Failure.................................765
				Alarm 16 - Memory Write Failure..................................766
				Alarm 17 - Memory Read Failure...................................766
				Alarm 18.........................................................767
				Alarm 19.........................................................767
				Alarm 22.........................................................767
				Operator Switch Doesn't Work.....................................768
				Alarm 26 - User Switch Fault - SELECT............................768
				Alarm 27 - User Switch Fault - SET...............................768
				Connector Map....................................................769
				Connectors.......................................................770
		PLMIII CHECK OUT PROCEDURE...............................................771
			General Description..................................................771
			Tools Required.......................................................771
			Checkout Procedure...................................................771
			PLMIII CHECKOUT PROCEDURE CONFIRMATION...............................775
				Flashburn Programming............................................775
				Confirmation Checklist...........................................777
	Reserve Engine Oil System....................................................779
OPERATOR'S CAB...................................................................785
	Truck Cab....................................................................787
		Description..............................................................787
		Removal..................................................................788
		Installation.............................................................789
		Cab Door.................................................................790
			Removal..............................................................790
			Installation.........................................................790
			Door Adjustment......................................................790
			Door Jam Bolt Adjustment.............................................790
			Door Handle Plunger Adjustment.......................................792
			Replace Door Glass...................................................793
			Replace Door Window Regulator........................................797
			Replace Door Handle or Latch Assembly................................797
			Door and Door Hinge Seal Replacement.................................798
		Glass Replacement........................................................799
			Adhesive Bonded Windows..............................................799
			Windshield and Rear Glass............................................800
	Cab Components...............................................................803
		Windshield Wiper.........................................................803
		Windshield Washer........................................................805
	Operator Comfort.............................................................807
		Operator Seat............................................................807
			Adjustment...........................................................807
		Heater/ Air Conditioner Controls.........................................808
			Heater Components....................................................809
			Filter...............................................................810
	Operator Controls and Equipment..............................................813
		Steering Wheel and Controls..............................................814
			Steering Column......................................................814
		Pedal Controls...........................................................816
		Overhead Controls, Gauges, Etc...........................................817
		Center Console...........................................................818
			Hoist Control Lever..................................................819
		Instrument Panel and Indicator Lights....................................822
			Control Symbols......................................................822
		Instrument Panel.........................................................823
			Panel Gauges, Indicators and Controls................................824
		Overhead Status / Warning Indicator Lights...............................828
LUBRICATION AND SERVICE..........................................................835
	Lubrication and Service......................................................837
		Lubrication Specifications Charts........................................837
			Service Capacities...................................................837
			Hydraulic Tank Service and Filling Instructions......................837
			Radiator Filling Procedure...........................................838
			Anti-Freeze Specifications...........................................838
			Reserve Engine Oil System............................................838
			Lubrication Chart- Oil and Grease Specifications.....................839
		10 Hour (Daily) Lubrication and Maintenance Checks.......................840
		50 Hour Lubrication and Maintenance Checks...............................842
		100 Hour Lubrication and Maintenance Checks..............................843
		250 Lubrication and Maintenance Checks...................................844
		500 Hour Lubrication and Maintenance Checks..............................846
		1000 Hour Lubrication and Maintenance Checks.............................847
		2500 Hour Lubrication and Maintenance Checks.............................848
		5000 Hour Lubrication and Maintenance Checks.............................849
		10,000 Hour Lubrication and Maintenance Checks...........................849
	Automatic Lubrication System.................................................851
		General Description......................................................851
		System Components........................................................853
		System Operation.........................................................854
			Injector Operation...................................................856
		General Instructions.....................................................857
		System Checkout..........................................................860
			Pump Rebuild.........................................................861
			System Troubleshooting Chart.........................................864
		Preventative Maintenance Procedures......................................867
	Motorized Wheel Maintenance Schedule.........................................869
ALPHABETICAL INDEX...............................................................873
SYSTEM SCHEMATICS................................................................877
	HYDRAULIC BRAKE SCHEMATIC EG4934.............................................879
	HYDRAULIC SCHEMATIC EK4841...................................................880
	HE481 PLM III ELECTRICAL SCHEMATIC...........................................881
	ELECTRICAL SCHEMATIC XS2100..................................................882
		XS2101 INDEX AND SYMBOLS.................................................882
		XS2102 CIRCUIT NUMBER LOCATION...........................................883
		XS2103 COMPONENT LOCATOR.................................................884
		XS2104 COMPONENT LOCATOR.................................................885
		XS2105 POWER DISTRIBUTION - 24V..........................................886
		XS2106 POWER 18 ELEMENT 3 STEP RETARDING.................................887
		XS2107 POWER 18 ELEMENT 7 STEP RETARDING.................................888
		XS2108 POWER 20 ELEMENT 7 STEP RETARDING.................................889
		XS2109 DRIVE SYSTEM CONTROL CIRCUITS.....................................890
		XS2110 TWO DIGIT DISPLAY.................................................891
		XS2111 G.E. DIGITAL INPUTS, AUTO LUBE CONTROL............................892
		XS2112 REAR TAIL LIGHTS, DIMMER CONTROL..................................893
		XS2113 5 MINUTE IDLE, SPARE WIRES........................................894
		XS2114 WINDOWS, RADIO, GAUGES............................................895
		XS2115 CONTACTOR FEEDBACK................................................896
		XS2116 CONTACTOR COILS...................................................897
		XS2117 MACHINE CONTROL CIRCUITS..........................................898
		XS2118 ACCELERATOR, RETARD PEDALS........................................899
		XS2119 HYDRAULIC CONTROLS, ALARMS........................................900
		XS2120 HEATER/AC, WINDSHIELD WIPER CONTROLS..............................901
		XS2121 LIGHT CONTROL CIRCUITS............................................902
		XS2122 INSTRUMENT LIGHTS, DIAGNOSTIC PORTS...............................903
		XS2123 MOD. MINING DISPATCH..............................................904
		XS2124 CUMMINS QSK60 ENGINE..............................................905
		XS2125 CUMMINS QSK60 ENGINE..............................................906
		XS2126 ELECTRONIC HOIST CONTROLLER.......................................907
	EL0114 VHMS SCHEMATIC........................................................908

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