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Komatsu 830E Dump Truck Shop Manual SN A30650-A30661, A30663-A30676 – PDF DOWNLOAD
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Komatsu 830E Dump Truck Shop Manual
Book Code: CEBM008601
SERIAL NUMBERS:
- A30650 – A30661
- A30663 – A30676
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Description
Komatsu 830E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 830E Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 830E
Serial Number: A30650-A30661, A30663-A30676
Book Code: CEBM008601
Language: English
Pages: 809
File Format: Portable Document Format (PDF)
KOMATSU 830E DUMP TRUCK SHOP MANUAL SN A30650-A30661, A30663-A30676 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 830E 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 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 æ10% 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 “M” designates a Mechanical drive and 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 Dump Truck Shop Manual
COVER.................................................................................................................................................. 1 FOREWORD............................................................................................................................................... 3 TABLE OF CONTENTS...................................................................................................................................... 5 SECTION A - GENERAL INFORMATION........................................................................................................................ 7 GENERAL INFORMATION INDEX.......................................................................................................................... 7 STANDARD CHARTS AND TABLES..................................................................................................................... 47 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values....................................................................... 47 Standard Assembly Torques For 12-Point, Grade 9, Cap Screws (SAE)...................................................................... 48 Standard Metric Assembly Torque For Class 10.9 Cap Screws & Class 10 Nuts.............................................................. 48 Suggested* Sources for Rust Preventive Grease:......................................................................................... 48 TABLE XIII COMMON CONVERSION MULTIPLIERS....................................................................................................... 52 STORAGE AND IDLE MACHINE PREPARATION........................................................................................................... 53 SHORT TERM IDLE PERIODS.................................................................................................................... 53 PREPARATION FOR STORAGE.................................................................................................................... 54 REMOVAL FROM STORAGE....................................................................................................................... 55 RECONDITIONING AN IDLE VEHICLE............................................................................................................. 57 ENGINE OPERATION........................................................................................................................... 60 AFTER ENGINE HAS STARTED................................................................................................................... 61 ENGINE STORAGE-CUMMINS..................................................................................................................... 62 Engine Storage-(Short Term)............................................................................................................ 62 Prepare the Engine for Short Term Storage.............................................................................................. 62 Remove the Engine from Short Term Storage.............................................................................................. 62 Engine Storage- (Long Term)............................................................................................................ 63 6 Months to 24 Months.................................................................................................................. 63 Prepare the Engine for Long Term Storage............................................................................................... 63 Remove the Engine from Long Term Storage............................................................................................... 63 ENGINE STORAGE - DETROIT DIESEL............................................................................................................ 64 Preparing Engine For Storage........................................................................................................... 64 Extended Storage (more Than 30 Days)................................................................................................... 64 Temporary Storage (30 Days Or Less).................................................................................................... 64 PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE............................................................ 66 ELECTRIC DRIVE TRUCKS...................................................................................................................... 67 Storage Instructions and Procedures.................................................................................................... 67 Placing Equipment Into Storage......................................................................................................... 67 When Storing A Truck That Is Operational............................................................................................... 67 When Storing A Truck That Is Not Operational........................................................................................... 68 When Storing A Major Component......................................................................................................... 68 Periodic Inspections................................................................................................................... 69 Placing Equipment Into Service After Storage........................................................................................... 69 When A Truck Is Operational............................................................................................................ 69 When A Truck Is Not Operational........................................................................................................ 69 For The First Hour..................................................................................................................... 70 PRESERVATION AND STORAGE ALLISON TRANSMISSION.............................................................................................. 71 Storage, New Transmission.............................................................................................................. 71 Storage, One Year -- Without Oil....................................................................................................... 71 Storage, One Year With Oil (normally in a vehicle chassis)............................................................................. 71 Restoring Transmission to Service...................................................................................................... 71 SECTION B - STRUCTURES................................................................................................................................. 73 STRUCTURAL INDEX................................................................................................................................... 73 STRUCTURAL COMPONENTS.......................................................................................................................... 75 LADDERS.................................................................................................................................... 75 Removal................................................................................................................................ 75 Installation........................................................................................................................... 75 RIGHT HAND DECK............................................................................................................................ 76 Removal................................................................................................................................ 76 Installation........................................................................................................................... 76 CENTER AND LEFT HAND DECK COMPONENTS....................................................................................................... 77 FUEL TANK.................................................................................................................................. 78 Removal................................................................................................................................ 78 Installation........................................................................................................................... 78 SECTION C - ENGINE, FUEL, COOLING AND AIR CLEANER...................................................................................................... 85 ENGINE, FUEL, COOLING AND AIR CLEANER INDEX........................................................................................................ 85 POWER MODULE................................................................................................................................... 87 PREPARATION................................................................................................................................ 87 Removal................................................................................................................................ 87 Installation........................................................................................................................... 91 COOLING SYSTEM................................................................................................................................. 93 POWER TRAIN.................................................................................................................................... 97 ALTERNATOR REMOVAL PROCEDURE............................................................................................................... 97 Removal (Komatsu SSDA16V160 or SDA16V160 Engine)....................................................................................... 97 ENGINE/ALTERNATOR MATING................................................................................................................... 99 General Instructions................................................................................................................... 99 MEASURING PROCEDURE........................................................................................................................ 99 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine..........................................................................101 ENGINE.....................................................................................................................................102 Removal................................................................................................................................102 Service................................................................................................................................102 Installation...........................................................................................................................102 AIR FILTRATION SYSTEM..........................................................................................................................103 AIR CLEANER................................................................................................................................103 Operation..............................................................................................................................103 General Service Information............................................................................................................103 MAIN FILTER ELEMENT........................................................................................................................103 Removal................................................................................................................................103 Installation...........................................................................................................................104 SAFETY FILTER ELEMENT......................................................................................................................105 Removal................................................................................................................................105 Installation...........................................................................................................................105 AIR INTAKE TROUBLESHOOTING.................................................................................................................105 AIR CLEANER ASSEMBLY CLEANING..............................................................................................................105 Main Filter Cleaning...................................................................................................................105 Precleaner Section Cleaning............................................................................................................106 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION)...................................................................................................109 ELECTRIC SYSTEM (24VDC NON-PROPULSION) INDEX.......................................................................................................109 24VDC ELECTRIC SUPPLY SYSTEM...................................................................................................................111 ELECTRICAL SYSTEM DESCRIPTION..............................................................................................................111 BATTERY....................................................................................................................................111 Maintenance and Service................................................................................................................111 Troubleshooting........................................................................................................................111 BATTERY CHARGING SYSTEM (Niehoff)..........................................................................................................113 General Description....................................................................................................................113 TROUBLESHOOTING PROCEDURES (On-Truck)......................................................................................................113 Preliminary Checks.....................................................................................................................114 Test Setup.............................................................................................................................114 Test Procedure.........................................................................................................................114 Regulator Bypass Test..................................................................................................................115 ON VEHICLE TROUBLESHOOTING GUIDE - SELF ENERGIZED ALTERNATOR...................................................................................116 ALTERNATOR ELECTRICAL CONDITION - Low Voltage - High Voltage - No Voltage..................................................................116 PRELIMINARY PROCEDURES.................................................................................................................116 LOW VOLTAGE OUTPUT.................................................................................................................116 HIGH VOLTAGE OUTPUT................................................................................................................116 NO VOLTAGE OUTPUT..................................................................................................................116 TOOLS AND EQUIPMENT:...............................................................................................................116 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:...........................................................................................116 Low Maintenance Types:.................................................................................................................116 Maintenance Free types:................................................................................................................117 High-Cycle Maintenance Free Types:.....................................................................................................117 DEFINITIONS................................................................................................................................117 ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized........................................................................................118 NO ALTERNATOR OUTPUT.......................................................................................................................118 STATIC TEST - ENGINE OFF, KEY ON, BATTERY SWITCH ON....................................................................................118 GO TO ALTERNATOR”......................................................................................................................118 GO TO “R” TERMINAL ON ALTERNATOR.......................................................................................................118 RE-TEST CHARGING CIRCUIT FOR OPERATION with ENGINE RUNNING.............................................................................118 GO TO REGULATOR (IF REQUIRED)..........................................................................................................119 GO TO REGULATOR CONNECTOR ON ALTERNATOR................................................................................................119 24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE)..............................................................................................120 OPERATION..............................................................................................................................120 Pressure Switch....................................................................................................................121 Check Valve........................................................................................................................121 Timer Solenoid.....................................................................................................................121 MAINTENANCE............................................................................................................................121 Prelube System Operation Checks....................................................................................................121 Check Valve........................................................................................................................121 Timer Solenoid.....................................................................................................................121 Troubleshooting Prelube Starter Circuit............................................................................................122 24 VDC ELECTRIC START SYSTEM...................................................................................................................124 CRANKING MOTORS............................................................................................................................124 OPERATION..............................................................................................................................124 Removal............................................................................................................................124 Installation.......................................................................................................................124 CRANKING MOTOR TROUBLESHOOTING.............................................................................................................125 Preliminary Inspection.................................................................................................................125 No-Load Test...........................................................................................................................125 Interpreting Results of Tests..........................................................................................................125 Disassembly............................................................................................................................126 Cleaning and Inspection................................................................................................................128 Armature Servicing.....................................................................................................................128 Field Coil Checks......................................................................................................................128 Field Coil Removal.....................................................................................................................128 Solenoid Checks........................................................................................................................129 Test...................................................................................................................................129 Assembly...............................................................................................................................130 Bearing Replacement:...................................................................................................................130 Motor Assembly:........................................................................................................................130 Pinion Clearance.......................................................................................................................131 MAGNETIC SWITCH............................................................................................................................131 Installation...........................................................................................................................131 Coil Test..............................................................................................................................132 24VDC ELECTRICAL SYSTEM COMPONENTS.............................................................................................................133 ALARM INDICATING DEVICE (AID)..............................................................................................................133 Coolant Level/Flasher Card.............................................................................................................133 Temperature/Latch Card.................................................................................................................133 Oil Level Card.........................................................................................................................134 Temperature Card.......................................................................................................................134 Hot Switch Inverter Card (Slot 4)......................................................................................................134 Hot Switch Inverter Card (Slot 3)......................................................................................................134 Diode Matrix Without Sound Card........................................................................................................134 Diode Matrix With Sound Card...........................................................................................................134 BODY-UP SWITCH.............................................................................................................................134 Adjustment.............................................................................................................................135 Service................................................................................................................................135 HOIST LIMIT SWITCH.........................................................................................................................135 Adjustment.............................................................................................................................135 Service................................................................................................................................135 BATTERY EQUALIZER..........................................................................................................................136 Troubleshooting........................................................................................................................136 GROUND LEVEL SHUTDOWN......................................................................................................................136 24 VOLT RELAY AND DIODE BOARDS.............................................................................................................137 RELAY BOARDS...........................................................................................................................137 Description........................................................................................................................137 SERVICE................................................................................................................................138 RELAY BOARD COMPONENTS.................................................................................................................139 Relay Board 1 Turn Signal..........................................................................................................139 Relay Board 2 Payload Meter (Optional).............................................................................................139 Relay Board 3 Stop Lights..........................................................................................................140 Relay Board 4 Parking Brake........................................................................................................140 Relay Board 5 Head Lights..........................................................................................................140 Relay Board 6 Auxiliary Panel......................................................................................................141 DIODE BOARD 1..............................................................................................................................142 Diode Testing..........................................................................................................................142 CIRCUIT BREAKERS...........................................................................................................................142 SECTION E - ELECTRICAL PROPULSION AND CONTROL..........................................................................................................147 ELECTRIC PROPULSION AND CONTROL INDEX..............................................................................................................147 ELECTRICAL PROPULSION COMPONENTS...............................................................................................................151 GENERAL SYSTEM DESCRIPTION.................................................................................................................151 CONTROL SYSTEM.............................................................................................................................151 System Operation.......................................................................................................................152 FL275 Panel............................................................................................................................153 CARD REPLACEMENT...........................................................................................................................154 Removal................................................................................................................................154 Installation...........................................................................................................................154 Card Repair............................................................................................................................154 Panel Wiring...........................................................................................................................154 COMPUTER DESCRIPTION.......................................................................................................................155 Microprocessor.........................................................................................................................155 Download Capability....................................................................................................................155 SOFTWARE...................................................................................................................................155 Base Monitor Program...................................................................................................................155 Runtime Monitor Program - OBJ Running Code.............................................................................................155 Configuration Software - CFG...........................................................................................................156 PTU - Portable Test Unit Code..........................................................................................................156 System Regulation......................................................................................................................156 Propulsion.............................................................................................................................157 Retarding..............................................................................................................................157 TWO-DIGIT DISPLAY PANEL....................................................................................................................158 The Coded Number.......................................................................................................................158 Events.................................................................................................................................158 Frames.................................................................................................................................159 Windows................................................................................................................................159 System Categories......................................................................................................................159 Limits On Resetting Faults.............................................................................................................159 NA Faults..............................................................................................................................160 Event Sequence.........................................................................................................................160 Resetting Events.......................................................................................................................160 Event Descriptions.....................................................................................................................160 Subcode Descriptions...................................................................................................................160 2-DIGIT DISPLAY PANEL SUBCODES.............................................................................................................168 PORTABLE TEST UNIT (PTU).......................................................................................................................171 DESCRIPTION................................................................................................................................171 Operational Hints......................................................................................................................171 SOFTWARE INSTALLATION PREPARATION..........................................................................................................172 HARD DISK SPACE REQUIREMENTS...............................................................................................................172 SOFTWARE INSTALLATION ON PTU...............................................................................................................172 PTU/Truck Communication Problems.......................................................................................................173 THE MAIN MENU..............................................................................................................................174 Quit Menu..............................................................................................................................174 PTU Talk To Truck......................................................................................................................174 View PTU Saved Files...................................................................................................................174 List Stat Data Files...................................................................................................................174 Truck Setup (CFG)......................................................................................................................174 Select Truck Setup.....................................................................................................................174 Update CFG Version.....................................................................................................................174 Change PTU Password....................................................................................................................174 CONFIGURATION (CFG) FILE CONVERSION........................................................................................................176 Conversion Procedure...................................................................................................................176 Convert Old CFG files for New software.................................................................................................177 STATEX CONFIGURATION FILES.................................................................................................................180 0) Source Directory: . . ..............................................................................................................180 1) Select A Truck Configuration . . ...................................................................................................181 3) Change/View Serial and Model Numbers . . ...........................................................................................183 2) View Truck Configuration: Data Curves . . ..........................................................................................182 4) View Options . . ...................................................................................................................183 5) Change/View Truck Specifics . . ....................................................................................................185 6) Change/View Overspeeds . . .........................................................................................................187 7) Save a Truck Configuration, filename: . . ..........................................................................................188 8) Save Directory: . . ................................................................................................................189 CHANGE PTU PASSWORD........................................................................................................................190 PROGRAMMING THE TRUCK......................................................................................................................191 Connect PTU to the Truck...............................................................................................................191 Select Configuration File..............................................................................................................191 Activate The PTU Mode..................................................................................................................191 Check Object Code Version..............................................................................................................192 Download Configuration Files...........................................................................................................193 Date And Time..........................................................................................................................194 Event Data.............................................................................................................................195 Statistical Data.......................................................................................................................197 View Counters..........................................................................................................................197 View Profiles..........................................................................................................................197 Upload Statistical Data To A File......................................................................................................197 Statistical Data Codes - Counters......................................................................................................198 STATISTICAL DATA CODES - COUNTERS..........................................................................................................199 STATISTICAL DATA CODES - PROFILES..........................................................................................................204 TRUCK SPECIFIC INFORMATION.................................................................................................................208 Temporary Truck Settings...............................................................................................................209 MISCELLANEOUS FEATURES.....................................................................................................................210 Saving Data............................................................................................................................210 PTU Abbreviations......................................................................................................................211 Other Menu Selections..................................................................................................................211 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS.................................................................................................212 ALTERNATOR.................................................................................................................................212 ELECTRIC WHEEL MOTORS......................................................................................................................212 RETARDING GRIDS............................................................................................................................212 ELECTRONIC ACCELERATOR AND RETARD PEDALS...................................................................................................212 Removal................................................................................................................................212 Installation...........................................................................................................................212 Disassembly............................................................................................................................213 Reassembly.............................................................................................................................213 COOLING BLOWER WARNING SYSTEM..............................................................................................................213 Operation..............................................................................................................................213 Test...................................................................................................................................213 Removal................................................................................................................................214 Installation...........................................................................................................................214 ELECTRICAL CONTROL CABINET.....................................................................................................................215 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS.........................................................................................220 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III.............................................................................................221 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE................................................................................................227 GENERAL INFORMATION........................................................................................................................227 COMMUNICATIONS PORT CHECK..................................................................................................................228 PTU Hookup.............................................................................................................................228 4.0 SEQUENCE TESTS - (ENGINE NOT ON).......................................................................................................229 Preparation and Setup..................................................................................................................229 CONTROL SYSTEM SELF-TEST...................................................................................................................230 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT...................................................................................................230 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT.....................................................................................................231 PTU Setup..............................................................................................................................231 4.3 REVERSER AND PROPULSION CONTACTORS CHECK...............................................................................................232 4.4 NOT USED...............................................................................................................................233 4.5 RETARD CONTACTORS OPERATION CHECK......................................................................................................233 4.6 GROUND FAULT SENSING CHECK.............................................................................................................233 4.7 GROUND FAULT IN RETARD OPERATION CHECK.................................................................................................234 4.8 OVERRIDE OPERATION CHECK...............................................................................................................234 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK......................................................................................................235 4.10 OVERSPEED RETARD OPERATION CHECK......................................................................................................235 4.11 HOIST INTERLOCK OPERATION CHECK.......................................................................................................236 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK..............................................................................................236 Return to Main Menu....................................................................................................................236 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL...................................................................................237 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU..........................................................................................237 5.2 DIGITAL INPUT CHECKS...................................................................................................................238 5.3 DIGITAL OUTPUT CHECKS..................................................................................................................239 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL...........................................................................................243 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU...............................................................................................243 6.2 ANALOG INPUT CHECKS....................................................................................................................244 6.3 FREQUENCY INPUT CHECKS.................................................................................................................248 Return to Main Menu....................................................................................................................249 7.0 SPEED EVENT CHECKS.....................................................................................................................249 Preparation and Setup..................................................................................................................249 Setup PTU..............................................................................................................................249 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK................................................................................250 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK.....................................................................250 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK....................................................................250 7.4 OTHER SPEED EVENTS CHECKS..............................................................................................................250 Return to Main Menu....................................................................................................................250 8.0 RETARD SPEED CONTROL SYSTEM CHECK......................................................................................................251 Preparation and Setup..................................................................................................................251 Setup PTU..............................................................................................................................251 8.1 OVERSPEED PICKUP AND DROPOUT CHECK.....................................................................................................251 8.2 RETARD POT MAXIMUM SETTING CHECK.......................................................................................................251 8.3 RETARD POT MINIMUM SETTING CHECK.......................................................................................................251 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL.....................................................................................252 Return to Main Menu....................................................................................................................252 9.0 LOAD TEST USING TRUCK RETARD GRIDS.....................................................................................................252 Setup and Preparation..................................................................................................................252 PTU Setup..............................................................................................................................252 9.1 LOAD TEST..............................................................................................................................253 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING................................................................................................253 Setup PTU..............................................................................................................................253 10.1 RETARD CHECK..........................................................................................................................254 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT...........................................................................................255 11.1 BRAKE SYSTEM INTERLOCKS CHECK.........................................................................................................255 Preparation............................................................................................................................255 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT................................................................................................255 11.3 SYNC TRANSFORMER CHECKOUT.............................................................................................................256 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT............................................................................................256 11.5 BATTERY BOOST ADJUSTMENT..............................................................................................................256 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST...........................................................................................256 11.7 MOTOR ROTATION TEST...................................................................................................................257 11.8 GROUND FAULT CHECKS...................................................................................................................257 12.0 MISCELLANEOUS CHARTS..................................................................................................................258 12.1 WHEEL MOTOR GEAR RATIOS...............................................................................................................258 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS........................................................................................................259 12.3 ENGINE OPTIONS........................................................................................................................260 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE TABLE OF CONTENTS..........................................................................261 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS............................................................................................................263 DRIVE AXLE, SPINDLE AND WHEELS INDEX...............................................................................................................263 TIRES AND RIMS.................................................................................................................................265 FRONT TIRES AND RIMS.......................................................................................................................265 Removal................................................................................................................................265 Installation...........................................................................................................................266 REAR TIRES AND RIMS........................................................................................................................267 Removal................................................................................................................................267 Installation...........................................................................................................................268 RIM........................................................................................................................................269 Tire Removal...........................................................................................................................269 RIM AND TIRE PREPARATION...............................................................................................................269 LUBRICANTS.............................................................................................................................270 TIRE INSTALLATION......................................................................................................................270 FRONT WHEEL HUB AND SPINDLE....................................................................................................................273 WHEEL HUB AND SPINDLE ASSEMBLY.............................................................................................................273 Removal................................................................................................................................273 Spindle Pusher Tool Usage..............................................................................................................274 Installation...........................................................................................................................275 Disassembly............................................................................................................................277 Cleaning and Inspection................................................................................................................277 Assembly...............................................................................................................................278 Wheel Bearing Adjustment (Tire Removed)................................................................................................280 Wheel Bearing Adjustment (Tire mounted)................................................................................................280 STEERING CYLINDERS AND TIE ROD.............................................................................................................282 Spherical Bearing Wear Limits..........................................................................................................282 Removal................................................................................................................................283 Installation...........................................................................................................................283 Bearing Replacement....................................................................................................................283 TOE-IN ADJUSTMENT......................................................................................................................285 REAR AXLE HOUSING ATTACHMENT...................................................................................................................287 PIVOT PIN..................................................................................................................................287 Removal................................................................................................................................287 Installation...........................................................................................................................287 PIVOT EYE BEARING..........................................................................................................................288 Disassembly............................................................................................................................288 Assembly...............................................................................................................................288 PIVOT EYE REPAIR...........................................................................................................................289 Removal................................................................................................................................289 Disassembly............................................................................................................................289 Assembly...............................................................................................................................289 Installation...........................................................................................................................289 ANTI-SWAY BAR..............................................................................................................................290 Removal................................................................................................................................290 Installation...........................................................................................................................290 Disassembly............................................................................................................................290 Assembly...............................................................................................................................290 Cleaning and Inspection................................................................................................................290 REAR AXLE HOUSING..............................................................................................................................291 REAR AXLE HOUSING..........................................................................................................................291 Removal................................................................................................................................291 Installation...........................................................................................................................291 WHEEL MOTOR................................................................................................................................291 Removal................................................................................................................................291 Cleaning and Inspection................................................................................................................292 Installation...........................................................................................................................292 Maximum Cap Screw Usage................................................................................................................292 SECTION H - HYDRAIR II SUSPENSIONS.....................................................................................................................293 HYDRAIR® II SUSPENSIONS INDEX......................................................................................................................293 FRONT SUSPENSION...............................................................................................................................295 Removal....................................................................................................................................295 Installation...............................................................................................................................296 MAXIMUM CAP SCREW USAGE....................................................................................................................297 “TURN-OF-THE-NUT” Tightening Procedure.................................................................................................298 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)........................................................................................299 Bearing Structure Removal..............................................................................................................299 Bearing Structure Installation.........................................................................................................299 MAJOR SUSPENSION REBUILD...................................................................................................................300 Disassembly............................................................................................................................300 Assembly...............................................................................................................................301 PRESSURE TEST..........................................................................................................................302 REAR SUSPENSIONS...............................................................................................................................303 Removal....................................................................................................................................303 Installation...............................................................................................................................305 Disassembly................................................................................................................................307 Cleaning and Inspection....................................................................................................................307 Assembly...................................................................................................................................307 PRESSURE TEST..............................................................................................................................308 OILING AND CHARGING PROCEDURE..................................................................................................................309 GENERAL....................................................................................................................................309 EQUIPMENT LIST.............................................................................................................................309 HYDRAIR® CHARGING KIT......................................................................................................................309 Installation of Charging Kit...........................................................................................................309 Removal of Charging Kit................................................................................................................310 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS..........................................................................................310 FRONT SUSPENSION...........................................................................................................................311 Front Suspension Oiling................................................................................................................311 Front Suspension Nitrogen Charging.....................................................................................................312 REAR SUSPENSION............................................................................................................................313 Rear Suspension Oiling.................................................................................................................313 Rear Suspension Nitrogen Charging......................................................................................................314 OIL AND NITROGEN SPECIFICATIONS CHART..........................................................................................................316 SECTION J - BRAKE CIRCUIT..............................................................................................................................317 BRAKE CIRCUIT INDEX................................................................................................................................317 BRAKE CIRCUIT COMPONENT SERVICE................................................................................................................325 BRAKE VALVE................................................................................................................................325 Rebuild Criteria.......................................................................................................................325 Removal................................................................................................................................325 DISASSEMBLY............................................................................................................................328 Cleaning and Inspection............................................................................................................330 ASSEMBLY...............................................................................................................................330 Actuator Base Threaded Inserts.....................................................................................................330 Boot and Cap.......................................................................................................................330 Valve Body Seal Installation.......................................................................................................331 Regulator Sleeve O-Ring Installation...............................................................................................331 Actuator Plunger O-ring Installation...............................................................................................331 Assembly of Valve..................................................................................................................332 DIFFERENTIAL PRESSURE SWITCH...........................................................................................................333 Disassembly........................................................................................................................333 Cleaning and Inspection............................................................................................................333 Assembly...........................................................................................................................333 VALVE BENCH TEST AND ADJUSTMENT........................................................................................................334 Test Set Up Procedure..............................................................................................................335 Brake Valve Output Pressure Adjustment.............................................................................................335 Differential Pressure Switch Test..................................................................................................335 Final Test and Adjustment..........................................................................................................336 Installation Of Brake Pedal Actuator Assembly to Brake Valve.......................................................................337 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal)...................................................338 Installation of Retard Pedal To Brake Pedal........................................................................................338 HYDRAULIC BRAKE ACCUMULATORS...........................................................................................................339 Brake Accumulator Bleed Down Procedure.............................................................................................339 Removal............................................................................................................................339 Installation.......................................................................................................................339 Disassembly........................................................................................................................339 Cleaning and Inspection............................................................................................................340 Assembly...........................................................................................................................341 Charging Procedure.................................................................................................................342 BRAKE MANIFOLD.........................................................................................................................343 Removal............................................................................................................................343 Removal............................................................................................................................343 Installation.......................................................................................................................344 Disassembly........................................................................................................................344 Cleaning and Inspection............................................................................................................344 Assembly...........................................................................................................................344 BRAKE CIRCUIT CHECK-OUT PROCEDURE..............................................................................................................345 EQUIPMENT REQUIRED.........................................................................................................................347 INITIAL SYSTEM SET-UP......................................................................................................................348 PARKING BRAKE..............................................................................................................................348 BRAKE SYSTEM CHECK-OUT.....................................................................................................................348 Failure Modes Check-Out................................................................................................................349 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING..............................................................................................351 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET..............................................................................355 KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET..................................................................................356 ROCKWELL WHEEL SPEED FRONT DISC BRAKES.........................................................................................................357 BRAKE CALIPER..............................................................................................................................357 Caliper Removal........................................................................................................................357 Installation...........................................................................................................................358 Disassembly............................................................................................................................359 Assembly...............................................................................................................................359 Cleaning and Inspection................................................................................................................360 BRAKE LINING...............................................................................................................................361 Replacement............................................................................................................................361 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE....................................................................................362 SAFETY PRECAUTIONS.....................................................................................................................362 FRONT BRAKE CONDITIONING...............................................................................................................362 BRAKE BLEEDING PROCEDURES..................................................................................................................364 ROCKWELL ARMATURE SPEED REAR DISC BRAKES.......................................................................................................365 REAR BRAKES................................................................................................................................365 CALIPER, DISC, AND PARKING BRAKE...........................................................................................................365 Caliper, Disc, and Parking Brake Removal...............................................................................................365 Caliper, Disc, And Parking Brake Installation..........................................................................................366 CALIPER, DISC, & PARKING BRAKE REMOVAL [For trucks equipped with one-piece adapter (16, Figure 6-3A)]..................................368 Caliper, Disc, And Parking Brake Installation..........................................................................................369 CALIPER PISTON.............................................................................................................................370 Piston Assembly Removal................................................................................................................370 Inspection.............................................................................................................................370 Piston Assembly Installation...........................................................................................................370 FUNCTIONAL TEST OF PISTON ASSEMBLY.....................................................................................................371 Return Spring Force................................................................................................................371 Built-In Clearance.................................................................................................................371 Grip Force.........................................................................................................................372 Grip Force Measurement.............................................................................................................373 Spring Force Measurement...........................................................................................................374 Disassembly of Piston Assembly.....................................................................................................375 Assembly of Piston Assembly........................................................................................................376 BENCH TEST.............................................................................................................................376 BRAKE LINING...........................................................................................................................377 Replacement........................................................................................................................377 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE......................................................................................380 General............................................................................................................................380 Safety Precautions.................................................................................................................380 Rear Brake Conditioning............................................................................................................381 BRAKE BLEEDING PROCEDURE...............................................................................................................382 ROCKWELL DISC PARKING BRAKE....................................................................................................................383 PARK BRAKE CALIPER.........................................................................................................................383 Removal................................................................................................................................383 Installation...........................................................................................................................384 Parking Brake Adjustment...............................................................................................................384 Park Brake Caliper Disassembly.........................................................................................................386 Cleaning and Inspection................................................................................................................386 Park Brake Caliper Assembly............................................................................................................387 PARK BRAKE LINING REPLACEMENT..............................................................................................................388 PARK BRAKE BURNISH PROCEDURE...........................................................................................................388 Lining Conditioning................................................................................................................388 BRAKE BLEEDING PROCEDURE...................................................................................................................388 SECTION L - HYDRAULIC SYSTEM...........................................................................................................................389 HYDRAULIC SYSTEM INDEX.............................................................................................................................389 HYDRAULIC SYSTEM...............................................................................................................................391 HYDRAULIC SYSTEM OPERATION.................................................................................................................391 COMPONENT DESCRIPTION......................................................................................................................392 HYDRAULIC SYSTEM COMPONENT REPAIR..............................................................................................................395 HOIST PUMP.................................................................................................................................395 Removal................................................................................................................................395 Installation...........................................................................................................................396 Disassembly............................................................................................................................397 INSPECTION OF PARTS....................................................................................................................400 Assembly...........................................................................................................................401 HYDRAULIC TANK.............................................................................................................................406 Filling Instructions...................................................................................................................406 Removal................................................................................................................................406 Installation...........................................................................................................................407 HYDRAULIC TANK STRAINERS...............................................................................................................407 Removal............................................................................................................................407 Inspect and Clean..................................................................................................................407 Installation.......................................................................................................................407 HYDRAULIC TANK BREATHERS...............................................................................................................408 HOIST CIRCUIT FILTERS..................................................................................................................408 FILTER ELEMENT REPLACEMENT.............................................................................................................409 Removal............................................................................................................................409 INDICATOR SWITCH.......................................................................................................................409 STEERING CIRCUIT...............................................................................................................................411 STEERING CIRCUIT OPERATION.................................................................................................................411 COMPONENT DESCRIPTION......................................................................................................................412 STEERING CONTROL UNIT..................................................................................................................412 FLOW AMPLIFIER.........................................................................................................................412 No Steer...........................................................................................................................414 Steering Left......................................................................................................................416 Steering Right.....................................................................................................................418 No Steer, External Shock Load......................................................................................................420 BLEED DOWN MANIFOLD....................................................................................................................422 ACCUMULATORS...........................................................................................................................423 Low Precharge Warning Switch.......................................................................................................423 HIGH PRESSURE FILTER...................................................................................................................423 STEERING/BRAKE PUMP....................................................................................................................423 Operation..........................................................................................................................424 PRINCIPLE OF OPERATION.............................................................................................................426 Full Pump Volume:..............................................................................................................426 Half Pump Volume:..............................................................................................................426 STEERING CIRCUIT COMPONENT REPAIR..............................................................................................................429 BLEED DOWN MANIFOLD........................................................................................................................429 Removal................................................................................................................................429 Installation...........................................................................................................................429 ACCUMULATOR................................................................................................................................430 Removal................................................................................................................................430 Installation...........................................................................................................................431 Disassembly............................................................................................................................432 Cleaning and Inspection................................................................................................................432 Assembly...............................................................................................................................433 TESTING................................................................................................................................433 FLOW AMPLIFIER.............................................................................................................................435 Removal................................................................................................................................435 Installation...........................................................................................................................435 Disassembly............................................................................................................................436 Reassembly.............................................................................................................................439 STEERING CONTROL UNIT......................................................................................................................440 Removal................................................................................................................................440 Spline Inspection......................................................................................................................440 Installation...........................................................................................................................440 Disassembly............................................................................................................................441 Cleaning and Inspection................................................................................................................442 Assembly...............................................................................................................................442 STEERING CYLINDER..........................................................................................................................446 Disassembly............................................................................................................................446 Inspection and Cleaning................................................................................................................446 Assembly...............................................................................................................................446 STEERING CIRCUIT FILTER....................................................................................................................447 FILTER ELEMENT REPLACEMENT.............................................................................................................447 Removal............................................................................................................................448 Installation.......................................................................................................................448 INDICATOR SWITCH.......................................................................................................................448 STEERING AND BRAKE PUMP....................................................................................................................449 Removal................................................................................................................................449 Installation...........................................................................................................................449 Disassembly............................................................................................................................451 Control Piston Group...................................................................................................................451 Valve Plate Group......................................................................................................................451 Rotating Group.........................................................................................................................452 Swashblock Group.......................................................................................................................452 Driveshaft Group.......................................................................................................................452 INSPECTION.............................................................................................................................452 Control Piston Group...................................................................................................................452 Rotating Group.........................................................................................................................452 Valve Plate Group......................................................................................................................452 Swashblock Group.......................................................................................................................456 Driveshaft Group.......................................................................................................................456 Compensator Block and Unloader Module..................................................................................................456 Stroke Adjuster Assembly...............................................................................................................456 ASSEMBLY...............................................................................................................................456 Swashblock Group.......................................................................................................................456 Control Piston Group...................................................................................................................458 Valve Plate Group......................................................................................................................458 HOIST CIRCUIT..................................................................................................................................461 HOIST CIRCUIT OPERATION....................................................................................................................461 COMPONENT DESCRIPTION......................................................................................................................462 HOIST VALVE............................................................................................................................463 HOIST PILOT VALVE......................................................................................................................464 HOIST-UP LIMIT SOLENOID................................................................................................................464 PILOT OPERATED CHECK VALVE.............................................................................................................464 COUNTERBALANCE VALVE MANIFOLD..........................................................................................................464 HOIST SYSTEM OPERATION MODES...............................................................................................................390 FLOAT POSITION OF PILOT VALVE AND BODY ON FRAME (Figure 7-6)...........................................................................466 POWER UP OPERATION (Figure 7-7)........................................................................................................468 HOLD OPERATION (Figure 7-8)............................................................................................................470 POWER DOWN OPERATION (Figure 7-9)......................................................................................................472 FLOAT OPERATION (Figure 7-10)..........................................................................................................474 HOIST CIRCUIT COMPONENT REPAIR.................................................................................................................477 HOIST VALVE................................................................................................................................477 Removal................................................................................................................................477 Installation...........................................................................................................................477 O-Ring Replacement.....................................................................................................................478 INLET SECTION..........................................................................................................................478 Disassembly........................................................................................................................478 Cleaning and Inspection............................................................................................................479 Assembly...........................................................................................................................480 SPOOL SECTION..........................................................................................................................480 Disassembly........................................................................................................................480 Cleaning and Inspection............................................................................................................482 Assembly...........................................................................................................................482 HOIST PILOT VALVE..........................................................................................................................483 Removal................................................................................................................................483 Installation...........................................................................................................................483 Disassembly............................................................................................................................483 Cleaning and Inspection................................................................................................................485 Assembly...............................................................................................................................485 BODY UP LIMIT SOLENOID.....................................................................................................................486 PILOT OPERATED CHECK VALVE.................................................................................................................486 HOIST CYLINDERS............................................................................................................................486 Removal................................................................................................................................486 Installation...........................................................................................................................487 Disassembly............................................................................................................................489 Cleaning and Inspection................................................................................................................490 ASSEMBLY OF QUILL AND CYLINDER.............................................................................................................491 Quill Installation.....................................................................................................................491 Installation of Check Balls and Plugs in Quill.........................................................................................492 Assembly of Cylinder...................................................................................................................493 COUNTERBALANCE MANIFOLD....................................................................................................................494 The counterbalance manifold is located to the rear of the hoist valve. The internal counterbalance valve relieves excessive pres.......494 DISABLED TRUCK DUMPING PROCEDURE.......................................................................................................495 HOOKUP.................................................................................................................................495 DUMPING PROCEDURE......................................................................................................................495 HYDRAULIC CHECKOUT PROCEDURE...................................................................................................................497 STEERING AND BRAKE PUMP....................................................................................................................497 Pressure Check And Adjustment Procedure................................................................................................497 BLEEDDOWN MANIFOLD.........................................................................................................................498 SHOCK & SUCTION VALVES.....................................................................................................................499 Shock & Suction Valve Settings.........................................................................................................499 LEAKAGE TESTS..............................................................................................................................500 Steering Control Unit & Flow Amplifier.................................................................................................500 Bleeddown Manifold.....................................................................................................................500 ACCUMULATOR BLEED DOWN PROCEDURE...........................................................................................................501 LOW STEERING PRESSURE SWITCH...............................................................................................................501 CHECKING HOIST SYSTEM PRESSURES............................................................................................................508 Hoist System Relief Pressure Adjustment................................................................................................508 Power Down Relief Pressure Adjustment..................................................................................................509 Hoist Counterbalance Valve Adjustment..................................................................................................510 Preparation:...........................................................................................................................510 Counterbalance Valve Pressure Check Only:..............................................................................................510 Counterbalance Valve Adjustment........................................................................................................511 HYDRAULIC SYSTEM FLUSHING PROCEDURE........................................................................................................514 OIL CLEANLINESS CHECK..................................................................................................................515 SECTION M - OPTIONS AND SPECIAL TOOLS..................................................................................................................517 OPTIONS AND SPECIAL TOOLS INDEX....................................................................................................................517 FIRE CONTROL SYSTEM (MANUAL)...................................................................................................................519 Operation..................................................................................................................................519 Inspection and Maintenance.................................................................................................................519 Recharging Procedures......................................................................................................................520 ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM............................................................................................521 SYSTEM ADJUSTMENT..........................................................................................................................521 PUMP.......................................................................................................................................521 Removal................................................................................................................................521 Disassembly............................................................................................................................521 Inspection.............................................................................................................................523 Assembly...............................................................................................................................523 Installation...........................................................................................................................524 BLOWER DRIVE MOTOR.........................................................................................................................524 Removal................................................................................................................................525 Disassembly............................................................................................................................525 Inspection Of Parts....................................................................................................................526 Assembly...............................................................................................................................526 Installation...........................................................................................................................527 BLOWER BEARING REPAIR......................................................................................................................527 Removal................................................................................................................................527 Replacement............................................................................................................................527 Assembly...............................................................................................................................528 AIR CLEANER................................................................................................................................528 Assembly...............................................................................................................................528 Removal................................................................................................................................528 Washing Air Cleaner....................................................................................................................528 Assembly...............................................................................................................................528 WIGGINS QUICK FILL FUEL SYSTEM.................................................................................................................529 FUEL RECEIVER..............................................................................................................................529 TANK BREATHER VALVE........................................................................................................................530 Removal................................................................................................................................530 Installation...........................................................................................................................530 Disassembly............................................................................................................................530 Assembly...............................................................................................................................530 LEFT SIDE FILL.............................................................................................................................531 BUCKEYE QUICK FUEL SYSTEM......................................................................................................................533 FUEL TANK BREATHER VALVE...................................................................................................................533 Maintenance............................................................................................................................533 Filter Service.........................................................................................................................533 Disassembly............................................................................................................................533 Inspection.............................................................................................................................533 Assembly...............................................................................................................................533 FUEL RECEIVER..............................................................................................................................534 ENGINE COOLANT HEATER..........................................................................................................................535 Maintenance................................................................................................................................535 HEATING ELEMENT............................................................................................................................535 Removal................................................................................................................................535 Installation...........................................................................................................................535 THERMOSTAT.................................................................................................................................536 Removal................................................................................................................................536 Installation...........................................................................................................................536 SPECIAL TOOLS..................................................................................................................................537 AIR CONDITIONING SYSTEM........................................................................................................................543 Environmental Impact.......................................................................................................................543 OPERATOR CAB AIR CONDITIONING..............................................................................................................544 PRINCIPLES OF REFRIGERATION................................................................................................................544 Air Conditioning.......................................................................................................................544 Refrigeration - The Act Of Cooling.....................................................................................................545 The Refrigeration Cycle................................................................................................................545 AIR CONDITIONER SYSTEM COMPONENTS..........................................................................................................546 Compressor (Refrigerant Pump)..........................................................................................................546 Service Valves.........................................................................................................................546 Condenser..............................................................................................................................546 Expansion Block Valve..................................................................................................................547 Evaporator.............................................................................................................................547 ELECTRICAL CIRCUIT.........................................................................................................................548 Thermostat.............................................................................................................................548 Compressor Clutch......................................................................................................................548 Trinary™ Switch........................................................................................................................549 SYSTEM SERVICING...........................................................................................................................550 SYSTEM OIL.................................................................................................................................551 Handling and Reusing PAG Oil...........................................................................................................551 Oil Quantity...........................................................................................................................551 Replacing Oil After Servicing the System...............................................................................................551 Setting Up a New Compressor............................................................................................................551 REFRIGERANT................................................................................................................................552 Recycled Refrigerant...................................................................................................................552 Reclaimed Refrigerant..................................................................................................................552 Refrigerant Quantity...................................................................................................................552 R-134a Refrigerant Containers..........................................................................................................552 SERVICE TOOLS AND EQUIPMENT................................................................................................................553 Recovery/Recycle Station...............................................................................................................553 Leak Detector..........................................................................................................................553 Service Valves.........................................................................................................................554 Vacuum Pump............................................................................................................................554 Manifold Gauge Set.....................................................................................................................555 Installing Manifold Gauge Set..........................................................................................................556 Purging Air From Service Hoses.........................................................................................................557 Stabilizing the AC System..............................................................................................................558 SYSTEM PERFORMANCE TEST....................................................................................................................558 SYSTEM LEAK TESTING........................................................................................................................559 Electronic leak detector...............................................................................................................559 Tracer dyes............................................................................................................................559 Soap and water.........................................................................................................................559 SYSTEM REPAIR..............................................................................................................................560 System Cleaning........................................................................................................................560 Hoses and Fittings.....................................................................................................................560 Lines..................................................................................................................................560 Expansion Valve........................................................................................................................560 Receiver-Drier.........................................................................................................................561 Thermostat.............................................................................................................................561 Compressor.............................................................................................................................561 Clutch.................................................................................................................................561 Servicing the Compressor Clutch........................................................................................................562 Pulley Removal.........................................................................................................................564 Clutch Coil Check......................................................................................................................564 Pulley Installation....................................................................................................................564 Clutch Assembly Installation...........................................................................................................565 RECOVERING AND RECYCLING THE REFRIGERANT...................................................................................................566 Performing the Recovery Cycle..........................................................................................................566 Performing the Recycling Procedure.....................................................................................................566 Evacuating and Charging the AC System..................................................................................................566 EVACUATING THE SYSTEM......................................................................................................................567 CHARGING THE AC SYSTEM.....................................................................................................................568 TROUBLESHOOTING............................................................................................................................569 Pre-Diagnosis Checks...................................................................................................................569 Preparing For Diagnosis................................................................................................................569 Preliminary Steps......................................................................................................................569 System Performance Test................................................................................................................569 Diagnosis Of Gauge Readings And System Performance.....................................................................................570 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM............................................................................................577 RADIATOR SHUTTERS..............................................................................................................................579 OPERATION..................................................................................................................................579 Hydraulic Circuit......................................................................................................................579 Electrical Circuit:....................................................................................................................580 MAINTENANCE AND REPAIR.....................................................................................................................580 TROUBLESHOOTING............................................................................................................................582 Hydraulic Troubleshooting..............................................................................................................585 Electrical Troubleshooting.............................................................................................................587 Electrical troubleshooting.............................................................................................................588 SECTION M20 PAYLOAD METER III ™ INDEX..........................................................................................................591 OPERATION SECTION..........................................................................................................................595 Introduction...........................................................................................................................595 Data Summary.......................................................................................................................595 Data Gathering.....................................................................................................................595 COMPONENT DESCRIPTION..................................................................................................................596 System Diagram.....................................................................................................................596 Inclinometer.......................................................................................................................596 Suspension Pressure Sensors........................................................................................................596 Operator Display...................................................................................................................596 Operator Switch....................................................................................................................597 Speed Input........................................................................................................................597 Body-Up Switch.....................................................................................................................597 Brake Lock Switch..................................................................................................................597 Payload Meter......................................................................................................................597 Communications Ports...............................................................................................................597 Key Switch Input...................................................................................................................598 Payload Meter Power................................................................................................................598 Load Lights........................................................................................................................598 Wiring and Termination.............................................................................................................599 TCI Outputs........................................................................................................................599 OPERATOR’S DISPLAY AND SWITCH..........................................................................................................600 Reading the Speedometer............................................................................................................600 Reading the Load Display...........................................................................................................600 Using the Operator ID..............................................................................................................600 Using the Load and Ton Counter.....................................................................................................600 Total Ton Counter..................................................................................................................600 Total Load Counter.................................................................................................................601 Clearing the Counters..............................................................................................................601 Viewing Live Sensor Data...........................................................................................................601 Other Display Messages.............................................................................................................601 PAYLOAD OPERATION & CALCULATION........................................................................................................602 Description of Haul Cycle States...................................................................................................602 Haul Cycle Description.............................................................................................................602 Load Calculation...................................................................................................................603 Carry Back.........................................................................................................................603 Measurement Accuracy...............................................................................................................603 SOURCES FOR PAYLOAD ERROR..............................................................................................................603 Payload Error......................................................................................................................603 Loading Conditions.................................................................................................................604 Pressure Sensors...................................................................................................................604 Swingloads.........................................................................................................................604 Speed and Distance.................................................................................................................604 HAUL CYCLE DATA........................................................................................................................604 Haul Cycle Warning Flags...........................................................................................................606 Frame Torque Data..................................................................................................................607 Sprung Weight Data.................................................................................................................607 Maximum Speed Data.................................................................................................................607 Alarm Records......................................................................................................................607 Fault Code Data....................................................................................................................608 PC SOFTWARE OVERVIEW...................................................................................................................609 System Configuration...............................................................................................................609 Installing the PLMIII Software.....................................................................................................609 DOWNLOADING DATA.......................................................................................................................610 PLM III SYSTEM CONFIGURATION...........................................................................................................611 Starting Communications............................................................................................................611 Displayed Payload Units............................................................................................................611 Time Units.........................................................................................................................611 Connection Menu....................................................................................................................611 Connecting to the Payload Meter....................................................................................................612 Configure the Payload Meter........................................................................................................612 Setting the Date and Time..........................................................................................................612 Setting the Truck Type.............................................................................................................613 Setting the Gauge Display Units....................................................................................................613 Setting the Frame Serial Number....................................................................................................613 Setting the Truck Number...........................................................................................................613 Setting the Komatsu Distributor....................................................................................................613 Setting the Komatsu Customer.......................................................................................................613 Clean Truck Tare...................................................................................................................614 Inclinometer Calibration...........................................................................................................614 DATA ANALYSIS..........................................................................................................................615 Creating a Query...................................................................................................................615 Sorting on Truck Unit Number.......................................................................................................615 Sorting on Truck Type..............................................................................................................615 Sorting on Date Range..............................................................................................................616 Sorting on Time Range..............................................................................................................616 Payload Detail Screen..............................................................................................................617 Creating Reports...................................................................................................................617 Summary - one page report..........................................................................................................618 Detailed - multi-page report.......................................................................................................618 Creating Graphs....................................................................................................................619 Exporting Data.....................................................................................................................619 CSV Export.........................................................................................................................619 Compressed.........................................................................................................................620 Importing Data.....................................................................................................................621 Deleting Haul Cycle Records........................................................................................................621 Viewing Alarms.....................................................................................................................622 Deleting Alarm Records.............................................................................................................622 TROUBLESHOOTING SECTION....................................................................................................................623 TROUBLESHOOTING........................................................................................................................623 Viewing Active Alarms..............................................................................................................623 Real-Time Data Display.............................................................................................................623 Testing the Payload Lights.........................................................................................................623 Creating Log Files of Inputs.......................................................................................................624 Daily Inspections..................................................................................................................624 Periodic Maintenance...............................................................................................................624 Abnormal Displays at Power-Up......................................................................................................625 No Payload Display When Key Switch is Turned ON....................................................................................626 No Display on Speedometer..........................................................................................................627 No Display on Operator Display.....................................................................................................627 No Communications With PC..........................................................................................................628 Load Lights Don’t Light During Loading.............................................................................................629 Load Lights Remain ON..............................................................................................................630 Load Lights Remain ON During Dumping...............................................................................................630 Display Doesn't Clear When The Load Is Dumped......................................................................................630 Calibration Problems...............................................................................................................631 Alarm 1 - Left Front Pressure High.................................................................................................632 Alarm 2 - Left Front Pressure Low..................................................................................................632 Troubleshoot Wiring to Left Front Suspension.......................................................................................632 Alarm 3 - Right Front Pressure High................................................................................................633 Alarm 4 - Right Front Pressure Low.................................................................................................633 Troubleshoot Wiring to Right Front Suspension......................................................................................633 Alarm 5 -Left Rear Pressure High...................................................................................................634 Alarm 6 - Left Rear Pressure Low...................................................................................................634 Troubleshoot Wiring to Left Rear Suspension........................................................................................634 Alarm 7 - Right Rear Pressure High.................................................................................................635 Alarm 8 - Right Rear Pressure Low..................................................................................................635 Troubleshoot Wiring to Right Rear Suspension.......................................................................................635 Alarm 9 - Inclinometer High........................................................................................................636 Alarm 10 - Inclinometer Low........................................................................................................636 Troubleshoot Inclinometer Wiring...................................................................................................636 Alarm 13 - Body Up Input Failure...................................................................................................637 Alarm 16 - Memory Write Failure....................................................................................................638 Alarm 17 - Memory Read Failure.....................................................................................................638 Alarm 18...........................................................................................................................639 Alarm 19...........................................................................................................................639 Alarm 22...........................................................................................................................639 Operator Switch Doesn't Work.......................................................................................................640 Alarm 26 - User Switch Fault - SELECT..............................................................................................640 Alarm 27 - User Switch Fault - SET.................................................................................................640 Connector Map......................................................................................................................641 Connectors.........................................................................................................................642 PLMIII CHECK OUT PROCEDURE.................................................................................................................643 General Description....................................................................................................................643 Tools Required.........................................................................................................................643 Checkout Procedure.....................................................................................................................643 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................................................................647 Flashburn Programming..............................................................................................................647 Confirmation Checklist.............................................................................................................649 RESERVE ENGINE OIL SYSTEM......................................................................................................................651 Extend oil change intervals................................................................................................................651 Operation..................................................................................................................................652 LED Monitor Light..........................................................................................................................652 Tank Fill Control (Optional)...............................................................................................................653 Service....................................................................................................................................654 Changing Oil...............................................................................................................................654 TROUBLESHOOTING............................................................................................................................655 System Electrical Schematics...........................................................................................................656 SECTION N - OPERATOR'S CAB.............................................................................................................................657 OPERATOR’S CAB INDEX...............................................................................................................................657 TRUCK CAB......................................................................................................................................659 CAB DOOR...................................................................................................................................662 Removal................................................................................................................................662 Installation...........................................................................................................................662 Door Adjustment........................................................................................................................662 Door Jamb Bolt Adjustment..............................................................................................................662 Door Handle Plunger Adjustment.........................................................................................................664 Replace Door Glass.....................................................................................................................665 Replace Door Window Regulator..........................................................................................................669 Replace Door Handle or Latch Assembly..................................................................................................669 Door and Door Hinge Seal Replacement...................................................................................................670 Door Opening Seal Removal..............................................................................................................670 Installation...........................................................................................................................670 GLASS REPLACEMENT......................................................................................................................671 ADHESIVE-BONDED WINDOWS............................................................................................................671 Replacement Procedure..........................................................................................................671 WINDSHIELD & REAR GLASS............................................................................................................672 Removal........................................................................................................................672 Installation...................................................................................................................673 Description................................................................................................................................659 Removal....................................................................................................................................660 Installation...............................................................................................................................661 CAB COMPONENTS.................................................................................................................................675 WINDSHIELD WIPER...........................................................................................................................675 Removal................................................................................................................................675 Installation...........................................................................................................................675 WINDSHIELD WASHER..........................................................................................................................676 Operation..............................................................................................................................676 Service................................................................................................................................676 OPERATOR COMFORT...............................................................................................................................677 OPERATOR SEAT..............................................................................................................................677 Adjustment.............................................................................................................................677 Removal................................................................................................................................677 Installation...........................................................................................................................677 HEATER/AIR CONDITIONER CONTROLS............................................................................................................678 OPERATION..............................................................................................................................678 HEATER/AIR CONDITIONER.................................................................................................................679 OPERATION..........................................................................................................................679 HEATER COMPONENTS......................................................................................................................679 CIRCUIT BREAKERS...................................................................................................................679 RELAYS.............................................................................................................................679 HEATER CORE........................................................................................................................680 FAN MOTOR AND SPEED CONTROL........................................................................................................680 Test...........................................................................................................................680 ACTUATORS..........................................................................................................................680 Test...........................................................................................................................680 FILTER.............................................................................................................................680 Service........................................................................................................................680 AIR CONDITIONER COMPONENTS.........................................................................................................680 OPERATOR CONTROLS AND EQUIPMENT................................................................................................................683 STEERING WHEEL AND CONTROLS................................................................................................................684 HORN BUTTON............................................................................................................................684 TILT / TELESCOPE LEVER.................................................................................................................684 TURN SIGNAL / HEADLIGHT DIMMER.........................................................................................................684 STEERING COLUMN........................................................................................................................684 Removal............................................................................................................................684 Spline Inspection..................................................................................................................685 Installation.......................................................................................................................685 SERVICE BRAKE PEDAL....................................................................................................................686 DYNAMIC RETARDER PEDAL.................................................................................................................686 THROTTLE PEDAL.........................................................................................................................686 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS......................................................................................687 DEFROSTER VENT CONTROL SWITCH..........................................................................................................687 OUTSIDE/INSIDE AIR CONTROL SWITCH......................................................................................................687 HEAT VENT CONTROL SWITCH...............................................................................................................687 TEMPERATURE CONTROL KNOB...............................................................................................................687 FAN CONTROL KNOB.......................................................................................................................687 HEATER/AIR CONDITIONER SELECTOR SWITCH.................................................................................................687 HEATER/AIR CONDITIONER VENTS...........................................................................................................687 INSTRUMENT PANEL...........................................................................................................................688 GRADE/SPEED WARNING CHART..............................................................................................................688 RADIO SPEAKERS.........................................................................................................................688 WARNING ALARM BUZZER...................................................................................................................688 CAB RADIO..............................................................................................................................688 WARNING LIGHTS DIMMER CONTROL..........................................................................................................688 STATUS / WARNING INDICATOR LIGHT PANEL.................................................................................................688 PAYLOAD METER (NOT SHOWN)..............................................................................................................688 WINDSHIELD WIPERS......................................................................................................................688 AIR CLEANER VACUUM GAUGES..............................................................................................................689 CENTER CONSOLE.............................................................................................................................689 HOIST CONTROL LEVER....................................................................................................................690 ASH TRAY...............................................................................................................................690 LIGHTER................................................................................................................................690 L.H. WINDOW CONTROL SWITCH.............................................................................................................690 R.H. WINDOW CONTROL SWITCH.............................................................................................................690 ENGINE SHUTDOWN SWITCH.................................................................................................................690 OVERRIDE SWITCH........................................................................................................................691 10, Figure 5-5: BLANK..............................................................................................................691 RETARD SPEED CONTROL (RSC) “OFF/ON” SWITCH.............................................................................................691 RETARD SPEED CONTROL (RSC) ADJUST DIAL.................................................................................................691 KOMATSU ENGINE QUANTUM CONNECTOR.......................................................................................................692 KOMATSU ENGINE CENSE CONNECTOR.........................................................................................................692 STATEX III PROPULSION SYSTEM DIAGNOSTIC CONNECTOR......................................................................................692 SPARE CONNECTOR LOCATION...............................................................................................................692 PASSENGER SEAT.........................................................................................................................692 INSTRUMENT PANEL AND INDICATOR LIGHTS..........................................................................................................693 CONTROL SYMBOLS............................................................................................................................693 INSTRUMENT PANEL...........................................................................................................................694 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 3-6)............................................................................................695 (1, Figure 5-6) KEY SWITCH.................................................................................................................695 (2, Figure 5-6) ENGINE SHUTDOWN SWITCH with TIMER DELAY (OPTIONAL).........................................................................695 (3, Figure 5-6) MANUAL BACKUP SWITCH.......................................................................................................695 (4, Figure 5-6) LADDER LIGHT SWITCH........................................................................................................695 (5, Figure 5-6) FOG LIGHTS (OPTIONAL)......................................................................................................696 (6, Figure 5-6) PANEL ILLUMINATION LIGHTS..................................................................................................696 (7, Figure 5-6) CAB AIR CONDITIONER / HEATER VENTS.........................................................................................696 (8, Figure 5-6) ENGINE COLD WEATHER STARTING AID (OPTIONAL)................................................................................696 (9, Figure 5-6) ROTATING BEACON LIGHT SWITCH (OPTIONAL)....................................................................................696 (10, Figure 5-6) HEATED MIRROR SWITCH (OPTIONAL)...........................................................................................696 (11, Figure 5-6) BLANK (Not Used In This Application)......................................................................................696 (12, Figure 5-6) WHEEL BRAKE LOCK CONTROL..................................................................................................696 (13, Figure 5-6) PARKING BRAKE CONTROL.....................................................................................................697 (14, Figure 5-6) TACHOMETER................................................................................................................697 (15, Figure 5-6) RIGHT TURN SIGNAL INDICATOR...............................................................................................697 (16, Figure 5-6) HIGH BEAM INDICATOR.......................................................................................................697 (17, Figure 5-6) LEFT TURN SIGNAL INDICATOR................................................................................................697 (18, Figure 5-6) SPEEDOMETER...............................................................................................................697 (19, Figure 5-6) VOLTMETER.................................................................................................................697 (20, Figure 5-6) ENGINE OIL PRESSURE GAUGE.................................................................................................697 (21, Figure 5-6) WATER TEMPERATURE GAUGE...................................................................................................698 (22, Figure 5-6) FUEL GAUGE................................................................................................................698 (23, Figure 5-6) (Not Used)................................................................................................................698 (24, Figure 5-6) HOURMETER.................................................................................................................698 (25, Figure 5-6) (Not Used)................................................................................................................698 (26, Figure 5-6) LIGHT SWITCH..............................................................................................................698 (27, Figure 5-6) WINDSHIELD WIPER and WASHER...............................................................................................698 (28, Figure 5-6) PANEL LIGHT DIMMER........................................................................................................698 INDICATOR LIGHT SYMBOLS....................................................................................................................700 D1. Electric System Fault..............................................................................................................701 E1. Low Brake Pressure.................................................................................................................701 A2. Low Hydraulic Tank Level (OPTIONAL)................................................................................................701 B2. Low Automatic Lubrication System Pressure..........................................................................................701 C2. Circuit Breaker Tripped............................................................................................................701 D2. Hydraulic Oil Filter Monitor.......................................................................................................701 E2. Low Fuel...........................................................................................................................701 A3. Parking Brake......................................................................................................................701 B3. Service Brake......................................................................................................................702 C3. Body Up............................................................................................................................702 D3. Dynamic Retarding..................................................................................................................702 E3. Stop Engine........................................................................................................................702 A4. NOT USED...........................................................................................................................702 B4. Manual Backup Lights...............................................................................................................703 C5. Motor Blower OFF...................................................................................................................704 D5, E5, A6, B6, C6, D6, E6: NOT USED...................................................................................................704 (7) HAZARD WARNING LIGHTS..............................................................................................................704 (8) LAMP TEST SWITCH...................................................................................................................704 SECTION P - LUBRICATION AND SERVICE....................................................................................................................705 LUBRICATION AND SERVICE INDEX......................................................................................................................705 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................................................................737 AXLE BOX...................................................................................................................................737 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................................................................738 ARMATURE AREA..............................................................................................................................738 AT TIRE CHANGE - FOR ALL MOTORIZED WHEELS..................................................................................................738 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................................................................739 GENERATOR / ALTERNATOR.....................................................................................................................739 GRID BLOWER MOTOR..........................................................................................................................739 CONTROL EQUIPMENT CHECKS...................................................................................................................739 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................................................................740 AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM.............................................................................................740 VEHICLE OPERATIONS TESTS...................................................................................................................740 SECTION Q - ALPHABETICAL INDEX.........................................................................................................................741 SECTION R - SYSTEM SCHEMATICS INDEX....................................................................................................................745 HYDRAULIC HOIST/STEERING SCHEMATIC.................................................................................................................747 HYDRAULIC BRAKE SCHEMATIC (STATEX III; LAPS).......................................................................................................748 STATEX III FL275 PANEL.............................................................................................................................749 PANEL CARD LOCATIONS...........................................................................................................................750 STATEX III FL328 PANEL.........................................................................................................................751 FB100 POWER SUPPLY CARD............................................................................................................................752 FB100 POWER SUPPLY CARD............................................................................................................................753 FB101 PROCESSOR CARD...............................................................................................................................754 FB101 PROCESSOR CARD...............................................................................................................................755 FB101 PROCESSOR CARD...............................................................................................................................757 FB140/149 ANALOG I/O CARD..........................................................................................................................758 FB140/149 ANALOG I/O CARD..........................................................................................................................759 FB155 DIGITAL I/O CARD.............................................................................................................................760 FB155 ANALOG I/O CARD/FB104 DIGITAL I/O CARD.......................................................................................................761 FB104 DIGITAL I/O CARD.............................................................................................................................762 FB104 DIGITAL I/O CARD.............................................................................................................................763 FB103 DIGITAL I/O CARD.............................................................................................................................764 FB103 DIGITAL I/O CARD.............................................................................................................................765 FB104 DIGITAL I/O CARD.............................................................................................................................766 CONNECTOR A........................................................................................................................................767 CONNECTOR B 1/3....................................................................................................................................768 CONNECTOR B 2/3....................................................................................................................................768 CONNECTOR B 3/3....................................................................................................................................769 CONNECTOR C 1/2....................................................................................................................................770 CONNECTOR C 2/2....................................................................................................................................771 CONNECTOR D 1/3....................................................................................................................................772 CONNECTOR D 2/3....................................................................................................................................773 CONNECTOR D 3/3....................................................................................................................................774 CONNECTOR E 1/4....................................................................................................................................775 CONNECTOR E 2/4....................................................................................................................................776 CONNECTOR E 3/4....................................................................................................................................777 CONNECTOR E 4/4....................................................................................................................................778 INDEX AND SYMBOLS ES0601 SHEET 1 OF 29.............................................................................................................779 CIRCUIT NUMBER LOCATOR ES0602 SHEET 2 OF 29........................................................................................................780 COMPONENT LOCATOR ES0603 SHEET 3 OF 29.............................................................................................................781 COMPONENT LOCATOR ES0604 SHEET 4 OF 29.............................................................................................................782 G.E. FAULT CODES ES0605 SHEET 5 OF 29..............................................................................................................783 G.E. FAULT CODES ES0606 SHEET 6 OF 29..............................................................................................................784 POWER DISTRIBUTION ES0607 SHEET 7 OF 29............................................................................................................785 POWER 18 ELEMENT 3 STEP RETARDING ES0608 SHEET 8 OF 29.............................................................................................786 POWER 18 ELEMENT 3 STEP RETARDING ES0609 SHEET 9 OF 29.............................................................................................787 POWER 20 ELEMENT 7 STEP RETARDING ES0610 SHEET 10 OF 29............................................................................................788 DRIVE SYSTEM CONTROL CIRCUITS ES0611 SHEET 11 OF 29................................................................................................789 TWO DIGIT DISPLAY ES0612 SHEET 12 OF 29............................................................................................................790 G.E. ANALOG INPUTS ES0613 SHEET 13 OF 29...........................................................................................................791 G.E. DIGITAL INPUTS, AUTO LUBE CONTROL / TEST ES0614 SHEET 14 OF 29................................................................................792 REAR TAIL LIGHTS, DIMMER CONTROL ES0615 SHEET 15 OF 29.............................................................................................793 5 MINUTE IDLE, SPARE WIRES ES0616 SHEET 16 OF 29...................................................................................................794 WINDOWS, RADIO, GAUGES ES0617 SHEET 17 OF 29.......................................................................................................795 CONTRACTOR FEEDBAK ES0618 SHEET 18 OF 29...........................................................................................................796 CONTRACTOR COILS ES0619 SHEET 19 OF 29.............................................................................................................797 MACHINE CONTROL CIRCUITS ES0620 SHEET 20 OF 29.....................................................................................................798 ACCELERATOR, RETARD PEDALS ES0621 SHEET 21 OF 29...................................................................................................799 HYDRAULIC CONTROLS, ALARMS ES0622 SHEET 22 OF 29...................................................................................................800 HEATER / AC, WINDSHIELD WIPER CONTROLS ES0623 SHEET 23 OF 29.......................................................................................801 LIGHT CONTROL CIRCUITS ES0624 SHEET 24 OF 29.......................................................................................................802 INSTRUMENT LIGHTS, DIAGNOSTIC PORTS ES0625 SHEET 25 OF 29..........................................................................................803 MOD, MINING DISPATCH ES0626 SHEET 26 OF 29.........................................................................................................804 CUMMINS QSK60 ENGINE ES0627 SHEET 27 OF 29.........................................................................................................805 CUMMINS QSK60 ENGINE ES0628 SHEET 28 OF 29.........................................................................................................806 4000 DDEC ENGINE ES0629 SHEET 29 OF 29.............................................................................................................807
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