Komatsu 830E Dump Truck Shop Manual SN A30662, A30677-A30688 – PDF DOWNLOAD

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: A30662, A30677-A30688
Book Code: CEBM008900
Language: English
Pages:786
File Format: Portable Document Format (PDF)

KOMATSU 830E DUMP TRUCK SHOP MANUAL SN A30662, A30677-A30688 – 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 ±10% tolerance unless otherwise specified.
•  A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model.
• The letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.

TABLE OF CONTENTS:

Komatsu 830E Dump Truck Shop Manual 

MAIN MENU..................................................................................  0
FOREWORD...................................................................................  5
CONTENTS...................................................................................  7
GENERAL INFORMATION........................................................................  9
	Truck Component Description and Specifications......................................... 11
	General Safety and Truck Operation..................................................... 15
		Precautions During Operation....................................................... 19
		Battery............................................................................ 24
		Precautions For Maintenance........................................................ 25
		During Maintenance................................................................. 26
		Tires.............................................................................. 29
		Additional Job Site Rules.......................................................... 30
		When Repairs Are Necessary......................................................... 31
		Operating Instructions............................................................. 33
	Warnings and Cautions.................................................................. 47
	Charts and Tables...................................................................... 55
	Storage Procedures..................................................................... 61
		Short Term Idle Periods............................................................ 61
		Preparation for Storage............................................................ 62
		Removal from Storage............................................................... 63
		Reconditioning an Idle Vehicle..................................................... 65
		Engine Operation................................................................... 68
		After Engine Has Started........................................................... 69
		Engine Storage-Cummins............................................................. 70
			Engine Storage (Short Term).................................................... 70
			Engine Storage (Long Term)..................................................... 71
		Engine Storage- Detroit Diesel..................................................... 72
			Preparing for Storage.......................................................... 72
			Temporary Storage (30 Days or Less)............................................ 72
			Extended Storage (More than 30 Days)........................................... 72
		Procedure for Restoring an Engine to Service Which Has Been in Extended Storage.... 74
		Electric Drive Trucks.............................................................. 75
		Preservation and Storage- Allison Transmission..................................... 79
STRUCTURES................................................................................. 81
	Structural Components.................................................................. 83
		Ladders............................................................................ 83
		Right Hand Deck.................................................................... 84
			Removal........................................................................ 84
			Installation................................................................... 84
		Center and Left Hand Deck Components............................................... 85
		Fuel Tank.......................................................................... 86
			Removal........................................................................ 86
			Installation................................................................... 86
	Dump Body.............................................................................. 87
		Removal............................................................................ 87
		Installation....................................................................... 88
		Body Pads.......................................................................... 89
			Adjustment..................................................................... 90
		Body Guide......................................................................... 90
		Body-Up Retention Cable............................................................ 90
		Body Position Indicator............................................................ 91
		Rock Ejectors...................................................................... 91
			Inspection..................................................................... 91
		Hoist Limit Switch................................................................. 91
		Body Up Switch..................................................................... 91
ENGINE..................................................................................... 93
	Power Module........................................................................... 95
		Preparation........................................................................ 95
			Removal........................................................................ 95
			Installation................................................................... 99
	Cooling System.........................................................................101
		Cooling System Description.........................................................101
		Radiator...........................................................................102
			Removal........................................................................102
			Installation...................................................................104
		Radiator Filling Procedure.........................................................104
	Power Train............................................................................105
		Alternator Removal Procedure.......................................................105
			Engine Alternator Mating.......................................................107
			Measuring Procedure............................................................107
			Joining Alternator and Engine..................................................109
		Engine.............................................................................110
			Removal........................................................................110
			Installation...................................................................110
	Air Filtration System..................................................................111
		Air Cleaner........................................................................111
			Operation......................................................................111
			General Service Information....................................................111
		Main Filter Element................................................................111
		Safety Filter Element..............................................................112
			Air Intake Troubleshooting.....................................................113
		Air Cleaner Assembly Cleaning......................................................113
			Main Filter Cleaning...........................................................113
			Precleaner Section Cleaning....................................................114
ELECTRICAL SYSTEM (24VDC NON-PROPULSION)...................................................117
	24VDC Electric Supply System...........................................................119
		Electrical System Description......................................................119
		Battery- Maintenance and Service...................................................119
			Troubleshooting................................................................119
		Battery Charging System (Niehoff)..................................................121
			General Description............................................................121
			Troubleshooting Procedures.....................................................121
			On Vehicle Troubleshooting Guide- Self Energized Alternator....................124
			Advanced System Troubleshooting................................................126
		24VDC Electric Starter System (with Prelube).......................................128
			Operation......................................................................128
			Maintenance....................................................................129
			Troubleshooting................................................................130
		24VDC Electric Start System........................................................132
			Troubleshooting................................................................133
	24VDC Electrical System Components.....................................................141
		Passenger Seat Base Compartment....................................................141
		Components.........................................................................141
		Alarm Indicating Device............................................................144
		Battery Equalizer..................................................................146
		Body-Up Switch.....................................................................147
		Hoist Limit Switch.................................................................147
		24Volt Relay and Diode Boards......................................................148
		Circuit Breaker Chart..............................................................154
ELECTRICAL PROPULSION COMPONENTS...........................................................155
	Electrical Propulsion Components.......................................................157
		General System Description.........................................................157
		Control System.....................................................................157
		FL275 Panel........................................................................159
			Card Replacement...............................................................160
			Card Repair....................................................................160
			Computer Description...........................................................161
			Software.......................................................................161
		2-Digit Display Panel..............................................................164
			Events.........................................................................164
			Frames.........................................................................165
			Windows........................................................................165
			2 Digit Display Panel Codes (Table I)..........................................167
			Subcode Descriptions (Table II)................................................174
		Portable Test Unit (PTU)...........................................................177
			Description....................................................................177
			Software Installation Preparation..............................................178
				The Main Menu..............................................................180
				PTU Software Menu Tree.....................................................181
				Configuration (CFG) File Conversion........................................182
			Statex Configuration Files.....................................................186
			Programming The Truck..........................................................197
				PTU Hookup.................................................................197
				Download Configuration Files...............................................199
			Event Data.....................................................................201
			Statistical Data...............................................................203
			Statistical Data Codes- Counters (Table III)...................................204
			Statistical Data Codes- Profiles (Table IV)....................................210
			Truck Specific Information.....................................................214
			Temporary Truck Settings.......................................................215
			Miscellaneous Software Features................................................216
				Saving Data................................................................216
				PTU Abbreviations..........................................................217
				Other Menu Selections......................................................217
		Miscellaneous Electrical Propulsion Components.....................................218
			Alternator.....................................................................218
			Electric Wheel Motors..........................................................218
			Electronic Accelerator and Retard Control......................................218
			Cooling Blower Warning System..................................................220
			Electrical Control Cabinet.....................................................221
		Statex III Electric Drive Components Abbreviations.................................226
	Statex III Electrical System Checkout Procedure........................................229
		General Information................................................................231
		Communications Port Check..........................................................232
			PTU Hookup.....................................................................232
		1.0 Sequence Tests.................................................................234
			Throttle System Check and Adjustment...........................................235
				Electronic Throttle System.................................................235
				Electronic Throttle System fuel Enhancement ("Fuel Saver").................236
			Retard System Check and Adjustment- Electronic Pedal System....................238
				Williams Electronic Retard Pedal and ACC/RET or RET Interface..............238
				Electronic Retard Pedal, Current Production Trucks.........................239
			Reverser and Propulsion Contractors Check......................................241
			Propulsion Lockout Test (DDEC&MTU Engine Trucks Only)..........................242
			Retard Contractors Operation Check.............................................243
			Ground Fault Sensing Check.....................................................243
			Ground Fault in Retard Operation Check.........................................243
			Override Operation Check.......................................................244
			Anti-Reversal Function (AR) Check..............................................245
			Overspeed Retard Operation Check...............................................245
			Hoist Interlock Operation Check................................................246
			Motor Blower Fault Light Operation Check.......................................247
		Digital Input/Output Signals Tests- FL275 Card Panel...............................248
			Setup Manual Digital Input/Output Test on PTU..................................248
			Digital Input Checks...........................................................249
			Digital Output Checks..........................................................251
		Analog Input Signals Test- FL275 Card Panel........................................254
			Setup Analog Input Monitor Screen on PTU.......................................254
			Analog Input Checks............................................................255
			Frequency Input Checks.........................................................262
		Speed Event Checks.................................................................264
			Single Speed Overspeed-Overspeed Settings Check................................265
			Empty Truck- 2 Speed Overspeed Settings Check..................................265
			Loaded Truck- 2 Speed Overspeed Settings Check.................................265
			Other Speed Events Checks......................................................265
		Retard Speed Control System Check..................................................267
			Overspeed Pickup and Dropout Check.............................................267
			Retard Pot Maximum Setting Check...............................................268
			Retard Pot Minimum Setting Check...............................................268
			Accelerator Pedal Override of Retard Speed Control.............................268
		Load Test Using Truck Retard Grids.................................................269
			Load Test......................................................................270
		Motor Field current Check in Retarding.............................................271
			Retard Check...................................................................271
		Miscellaneous Component Test and Adjustment........................................272
			Brake System Interlocks Check..................................................272
			Blower Loss Pressure Switch Adjustment.........................................273
			SYNC Transformer Checkout......................................................273
			Power Contactor Position Sensor Adjustment.....................................273
			Battery Boost Adjustment.......................................................274
			Isolation Amplifier& Voltage Module Test.......................................274
				Voltage Measuring Module Test (VMM1&VMM2)..................................274
				ISO-AMP Test...............................................................275
			Motor Rotation Test............................................................275
			Ground Fault Checks............................................................276
		Optional Payload Meter (PLM II) Check-Out Procedure................................277
			Check the Deck Mounted Lights..................................................277
			Check Pressure Sensors.........................................................277
			Check Operation of Data Storage Trigger Module.................................277
			Zero the Angle Sensor..........................................................277
			Check Body-Up Switch Function..................................................277
		Miscellaneous Charts...............................................................278
			Wheel Motor Gear Ratios........................................................278
			Maximum Allowable Truck Speeds.................................................279
			Engine Options.................................................................280
DRIVE AXLE, SPINDLE AND WHEELS.............................................................281
	Tires and Rims.........................................................................283
		Front Tires and Rims...............................................................283
			Removal........................................................................283
			Installation...................................................................284
		Rear Tires and Rims................................................................285
			Removal........................................................................285
			Installation...................................................................286
		Rim................................................................................287
			Tire Removal...................................................................287
			Rim and Tire Preparation.......................................................287
			Lubricants.....................................................................288
			Tire Installation..............................................................288
	Front Wheel Hub and Spindle............................................................291
		Wheel Hub and Spindle Assembly.....................................................291
			Removal........................................................................291
			Spindle Pusher Tool Usage......................................................292
			Installation...................................................................293
			Disassembly....................................................................295
			Cleaning and Inspection........................................................295
			Assembly.......................................................................296
			Wheel Bearing Adjustment.......................................................298
			Wheel Bearing Adjustment (Tire Mounted)........................................298
		Steering Cylinders and Tie Rod.....................................................300
			Spherical Bearing Wear Limits..................................................300
			Removal........................................................................301
			Installation...................................................................301
			Bearing Replacement............................................................301
		Toe-In Adjustment..................................................................303
	Rear Axle Housing Attachment...........................................................305
		Pivot Pin..........................................................................305
			Removal........................................................................305
			Installation...................................................................305
		Pivot Eye Bearing..................................................................306
			Disassembly....................................................................306
			Assembly.......................................................................306
		Pivot Eye Repair...................................................................307
			Removal........................................................................307
			Disassembly....................................................................307
			Assembly.......................................................................307
			Installation...................................................................307
		Anti-Sway Bar......................................................................308
			Removal........................................................................308
			Installation...................................................................308
			Disassembly....................................................................308
			Cleaning and Inspection........................................................308
			Assembly.......................................................................308
	Rear Axle Housing......................................................................309
		Rear Axle Housing..................................................................309
			Removal........................................................................309
			Installation...................................................................309
		Wheel Motor........................................................................309
			Removal........................................................................309
			Cleaning and Inspection........................................................310
			Installation...................................................................310
HYDRAIR II SUSPENSIONS.....................................................................311
	Front Suspension.......................................................................313
		Removal............................................................................313
		Installation.......................................................................314
			"Turn of the Nut" Tightening Procedure.........................................316
		Minor Repair.......................................................................317
			Bearing Structure Removal......................................................317
			Bearing Structure Installation.................................................317
		Major Suspension Rebuild...........................................................318
			Disassembly....................................................................318
			Assembly.......................................................................319
			Pressure Test..................................................................320
	Rear Suspension........................................................................321
		Removal............................................................................321
		Installation.......................................................................323
		Disassembly........................................................................325
		Cleaning and Inspection............................................................325
		Assembly...........................................................................325
		Pressure Test......................................................................326
	Oiling and Charging Procedure..........................................................327
		General............................................................................327
		Equipment List.....................................................................327
		Front Suspension...................................................................329
			Front Suspension Oiling........................................................329
			Front Suspension Nitrogen Charging.............................................330
		Rear Suspension....................................................................331
			Rear Suspension Oiling.........................................................331
			Rear Suspension Nitrogen Charging..............................................332
		Oil and Nitrogen Specifications Chart..............................................334
BRAKE CIRCUIT..............................................................................335
	Brake Circuit..........................................................................337
		Service Brake Circuit Operation....................................................337
		Secondary Braking and Automatic Apply..............................................339
		Parking Brake Circuit..............................................................339
		Brake Lock Circuit.................................................................340
		Warning Circuit....................................................................340
	Brake Circuit Component Service........................................................343
		Brake Valve........................................................................343
			Removal........................................................................343
			Installation...................................................................345
			Disassembly....................................................................346
			Cleaning and Inspection........................................................348
			Assembly.......................................................................348
		Differential Pressure Switch.......................................................351
			Disassembly....................................................................351
			Cleaning and Inspection........................................................351
			Assembly.......................................................................351
		Valve Bench Test and Adjustment....................................................352
			Test Set Up Procedure..........................................................353
			Differential Pressure Switch Test..............................................353
			Final Test and Adjustment......................................................354
		Installation of Brake Pedal Actuator Assembly to Brake Valve.......................355
		Brake Valves with Integral Mounted Electronic Retard Pedal.........................356
		Hydraulic Brake Accumulators.......................................................357
			Removal........................................................................357
			Installation...................................................................357
			Disassembly....................................................................357
			Cleaning and Inspection........................................................358
			Assembly.......................................................................359
	Brake Circuit Check-Out Procedure......................................................361
		Equipment Required.................................................................363
		Initial System Set-Up..............................................................364
		Parking Brake......................................................................364
		Brake System Check-Out.............................................................364
		Failure Modes Check-Out............................................................365
		Brake Circuit and Brake Valve Troubleshooting......................................367
		Hydraulic Brake System Check-Out Procedure Data Sheet..............................371
	Rockwell Wheel Speed Front Disc Brakes.................................................373
		Brake Caliper......................................................................373
		Brake Lining.......................................................................377
		Front Service Brake Conditioning (Burnishing) Procedure............................378
		Brake Bleeding Procedures..........................................................379
	Rockwell Armature Speed Rear Disc Brakes...............................................381
		Rear Brakes........................................................................381
		Caliper, Disc and Parking Brake....................................................381
		Caliper Piston.....................................................................386
		Bench Test.........................................................................392
		Brake Lining.......................................................................393
		Service Brake Conditioning (Burnishing) Procedure..................................396
		Brake Bleeding Procedure...........................................................398
	Rockwell Disc Parking Brake............................................................399
		Park Brake Caliper.................................................................399
			Removal........................................................................399
			Installation...................................................................400
			Parking Brake Adjustment.......................................................400
			Park Brake Caliper Disassembly.................................................402
			Cleaning and Inspection........................................................402
			Park Brake Caliper Assembly....................................................403
		Park Brake Lining Replacement......................................................404
		Park Brake Burnish Procedure.......................................................404
		Brake Bleeding Procedure...........................................................404
HYDRAULIC SYSTEM...........................................................................405
	Hydraulic System.......................................................................407
		Component Description..............................................................408
	Hydraulic System Component Repair......................................................411
		Hoist Pump.........................................................................411
		Hydraulic Tank.....................................................................422
			Hydraulic Tank Strainers.......................................................423
			Hydraulic Tank Breathers.......................................................424
			Hoist Circuit Filters..........................................................424
			Filter Element Replacement.....................................................425
	Steering Circuit.......................................................................427
		Steering Circuit Operation.........................................................427
		Component Description..............................................................428
			Steering Control Unit..........................................................428
			Flow Amplifier.................................................................428
			Bleed Down Manifold............................................................438
			Accumulators...................................................................439
			High Pressure Filter...........................................................439
			Steering/ Brake Pump...........................................................439
			Operation......................................................................440
	Steering Circuit Component Repair......................................................445
		Bleed Down Manifold................................................................445
		Accumulator........................................................................446
			Steering Accumulator Charging Procedure........................................450
		Flow Amplifier.....................................................................451
		Steering Control Unit..............................................................456
		Steering Cylinder..................................................................462
		Steering Circuit Filter............................................................463
		Steering and Brake Pump............................................................465
	Hoist Circuit..........................................................................477
		Hoist Circuit Operation............................................................477
		Component Description..............................................................478
			Hydraulic Tank.................................................................478
			Hoist Pump.....................................................................478
			High Pressure Filters..........................................................478
			Hoist Valve....................................................................479
			Hoist Pilot Valve..............................................................480
			Hoist Up Limit Solenoid........................................................480
			Pilot Operated Check Valve.....................................................480
			Counterbalance Valve Manifold..................................................480
		Hoist System Operation Modes.......................................................481
	Hoist Circuit Component Repair.........................................................493
		Hoist Valve........................................................................493
			Inlet Section..................................................................494
			Spool Section..................................................................496
		Hoist Pilot Valve..................................................................499
		Body Up Limit Solenoid.............................................................502
		Pilot Operated Check Valve.........................................................502
		Hoist Cylinders....................................................................502
		Counterbalance Manifold............................................................510
		Disabled Truck Dumping Procedure...................................................511
	Hydraulic Checkout Procedure...........................................................513
		Steering and Brake Pump............................................................513
		Bleed Down Manifold................................................................514
		Shock and Suction Valves...........................................................515
		Leakage Tests......................................................................516
		Troubleshooting Chart..............................................................518
			Steering Circuit...............................................................518
			Steering Pump..................................................................520
			Flow Amplifier.................................................................522
		Checking Hoist System Pressures....................................................524
		Hoist Counterbalance Valve Adjustment..............................................526
		Troubleshooting Guide (Hoist Pump).................................................528
		Hydraulic System Flushing Procedure................................................530
OPTIONS AND SPECIAL TOOLS..................................................................531
	Ansulfire Control System Manual........................................................533
		Operation..........................................................................533
		Inspection and Maintenance.........................................................533
		Recharging Procedures..............................................................534
	Alternator and Wheelmotor Cooling Air Filter System....................................535
		System Adjustment..................................................................535
		Pump...............................................................................535
		Blower Drive Motor.................................................................538
		Blower Bearing Repair..............................................................541
		Air Cleaner........................................................................542
	Wiggins Quick Fill Fuel System.........................................................543
		Fuel Receiver......................................................................543
		Tank Breather Valve................................................................544
	Buckeye Quick Fill Fuel System.........................................................547
		Tank Breather Valve................................................................547
		Fuel Receiver......................................................................548
	Engine Coolant Heater..................................................................549
		Heating Element....................................................................549
		Thermostat.........................................................................550
	Special Tools..........................................................................551
	Air Conditioning System................................................................557
		Environmental Impact...............................................................557
		Operator Cab Air Conditioning......................................................558
		Principles of Refrigeration........................................................558
		Air Conditioner System Components..................................................560
		Electrical Circuit.................................................................562
		System Servicing...................................................................564
		Service Tools and Equipment........................................................567
		Manifold Gauge Set.................................................................569
		System Performance Test............................................................572
		System Leak Testing................................................................573
		System Repair......................................................................574
		Evacuating the System..............................................................581
		Troubleshooting....................................................................583
		Preventive Maintenance Schedule for A/C Systems....................................591
	Radiator Shutters......................................................................593
	Payload Meter III......................................................................597
		Operation Section..................................................................600
		Introduction.......................................................................600
		Data Summary.......................................................................600
		Data Gathering.....................................................................600
		Component Description..............................................................601
			System Diagram.................................................................601
			Suspension Pressure Sensors....................................................601
			Inclinometer...................................................................601
			Operator Display...............................................................601
			Operator Switch................................................................602
			Speed Input....................................................................602
			Body Up Switch.................................................................602
			Brake Lock Switch..............................................................602
			Payload Meter..................................................................602
			Communications Ports...........................................................602
			Kewswitch Input................................................................603
			Payload Meter Power............................................................603
			Load Lights....................................................................603
			Wiring and Termination.........................................................604
			TCI Outputs....................................................................604
		Operator's Display and Switch......................................................605
			Reading the Speedometer........................................................605
			Reading the Load Display.......................................................605
			Using the Operator ID..........................................................605
			Using the Load and Ton Counter.................................................605
			Total Ton Counter..............................................................605
			Total Load Counter.............................................................606
			Clearing the Counters..........................................................606
			Viewing Live Sensor Data.......................................................606
			Other Display Messages.........................................................606
		Payload Operation & Calculation....................................................607
			Description of Haul Cycle States...............................................607
			States or Stages of a Typical Haul Cycle.......................................607
			Haul Cycle Description.........................................................607
			Load Calculation...............................................................608
			Carry Back.....................................................................608
			Measurement Accuracy...........................................................608
			Sources for Payload Error......................................................608
				Payload Error..............................................................608
				Loading Conditions.........................................................609
				Pressure Sensors...........................................................609
				Swing Loads................................................................609
				Speed and Distance.........................................................609
		Haul Cycle Data....................................................................609
			Haul Cycle Data................................................................610
			Haul Cycle Warning Flags.......................................................611
			Alarm Records..................................................................612
			Frame Torque Data..............................................................612
			Sprung Weight Data.............................................................613
			Maximum Speed Data.............................................................613
		PC Software Overview...............................................................613
			PC Overview....................................................................613
			System Configuration...........................................................613
			Installing the PLM III Software................................................613
		Downloading Data...................................................................614
		PLM III System Configuration.......................................................615
			Starting Communications........................................................615
			Displayed Payload Units........................................................615
			Time Units.....................................................................615
			Connection Menu................................................................615
			Connecting to the Payload Meter................................................616
			Configure the Payload Meter....................................................616
				Setting the Date and Time..................................................616
				Setting the Truck Type.....................................................617
				Setting the Gauge Display Units............................................617
				Setting the Frame Serial Number............................................617
				Setting the Truck Number...................................................617
				Setting the Komatsu Customer...............................................617
			Clean Truck Tare...............................................................618
			Inclinometer Calibration.......................................................618
		Data Analysis......................................................................619
			Creating a Query...............................................................619
			Sorting on Truck Type..........................................................619
			Sorting on Date Range..........................................................620
			Sorting on Time Range..........................................................620
			Payload Detail Screen..........................................................621
			Creating Reports...............................................................621
			Summary - One Page Report......................................................622
			Detailed - Multi Page Report...................................................622
			Creating Graphs................................................................623
			Exporting Data.................................................................623
			CSV Export.....................................................................623
			Compressed.....................................................................624
			Importing Data.................................................................625
			Deleting Haul Cycle Records....................................................625
			Viewing Alarms.................................................................626
			Deleting Alarm Records.........................................................626
		Troubleshooting Section............................................................627
			Troubleshooting................................................................627
			Viewing Active Alarms..........................................................627
			Real-Time Data Display.........................................................627
			Testing the Payload Lights.....................................................627
			Creating Log Files of Inputs...................................................628
			Daily Inspections..............................................................628
			Periodic Maintenance...........................................................628
			Abnormal Displays at Power-Up..................................................629
			No Payload Display When Key Switch is Turned ON................................630
			No Display on Speedometer......................................................631
			No Display on Operator Display.................................................631
			No Communication With PC.......................................................632
			Load Lights Don't Light During Loading.........................................633
			Load Lights Remain ON..........................................................634
			Load Lights Remain ON During Dumping...........................................634
			Display Doesn't Clear When the Load is Dumped..................................634
			Calibration Problems...........................................................635
			Alarm 1-Left Front Pressure High...............................................636
			Alarm 2-Left Front Pressure Low................................................636
			Troubleshoot Wiring to Left Front Suspension...................................636
			Alarm 3-Right Front Pressure High..............................................637
			Alarm 4-Right Front Pressure Low...............................................637
			Troubleshooting Wiring to Right Front Suspension...............................637
			Alarm 5-Left Rear Pressure High................................................638
			Alarm 6-Left Rear Pressure Low.................................................638
			Troubleshooting Wiring to Left Rear Suspension.................................638
			Alarm 7-Right Rear Pressure High...............................................639
			Alarm 8-Right Rear Pressure Low................................................639
			Troubleshoot Wiring to Right Rear Suspension...................................639
			Alarm 9-Inclinometer High......................................................640
			Alarm 10-Inclinometer Low......................................................640
			Troubleshoot Inclinometer Wiring...............................................640
			Alarm 13-Body Up Input Failure.................................................641
			Alarm 15-Memory Write Failure..................................................642
			Alarm 16 - Memory Read Failure.................................................642
			Alarm 24 - System Key-On Status................................................642
			Operator Switch Doesn't Work...................................................643
			Alarm 26 - User Switch Fault - Select..........................................643
			Alarm 27 - User Switch Fault - Set.............................................643
			Connector Map..................................................................644
			Connectors.....................................................................645
		PLM III Check Out Procedure........................................................647
			General Description............................................................647
			Tools Required.................................................................647
			Check Out Procedure............................................................647
			PLM III Check Out Procedure Confirmation.......................................651
				Flashburn Programming......................................................651
				Confirmation Checklist.....................................................653
		PLM III Components.................................................................654
			Pressure Sensor................................................................654
			Controller.....................................................................654
			Speedometer....................................................................654
	Reserve Engine Oil System..............................................................655
OPERATOR'S CAB.............................................................................661
	Truck Cab..............................................................................663
		Description........................................................................663
		Removal............................................................................664
		Installation.......................................................................665
		Cab Door...........................................................................666
			Removal........................................................................666
			Installation...................................................................666
			Door Adjustment................................................................666
			Door Jam Bolt Adjustment.......................................................666
			Door Handle Plunger Adjustment.................................................668
			Replace Door Glass.............................................................669
			Replace Door Window Regulator..................................................673
			Replace Door Handle or Latch Assembly..........................................673
			Door and Door Hinge Seal Replacement...........................................674
		Glass Replacement..................................................................675
			Adhesive Bonded Windows........................................................675
			Windshield and Rear Glass......................................................676
	Cab Components.........................................................................679
		Windshield Wiper...................................................................679
		Windshield Washer..................................................................681
	Operator Comfort.......................................................................683
		Operator Seat......................................................................683
			Adjustment.....................................................................683
		Heater/ Air Conditioner Controls...................................................684
			Heater Components..............................................................685
			Filter.........................................................................686
	Operator Controls and Equipment........................................................689
		Steering Wheel and Controls........................................................690
			Steering Column................................................................690
		Pedal Controls.....................................................................692
		Overhead Controls, Gauges, Etc.....................................................693
		Center Console.....................................................................694
			Hoist Control Lever............................................................695
		Instrument Panel and Indicator Lights..............................................698
			Control Symbols................................................................698
		Instrument Panel...................................................................699
			Panel Gauges, Indicators and Controls..........................................700
		Overhead Status / Warning Indicator Lights.........................................704
LUBRICATION AND SERVICE....................................................................711
	Lubrication and Service................................................................713
		Lubrication Specifications Charts..................................................713
			Service Capacities.............................................................713
			Hydraulic Tank Service and Filling Instructions................................713
			Radiator Filling Procedure.....................................................714
			Anti-Freeze Specifications.....................................................714
			Reserve Engine Oil System......................................................714
			Lubrication Chart- Oil and Grease Specifications...............................715
		10 Hour (Daily) Lubrication and Maintenance Checks.................................716
		50 Hour Lubrication and Maintenance Checks.........................................718
		100 Hour Lubrication and Maintenance Checks........................................719
		250 Lubrication and Maintenance Checks.............................................720
		500 Hour Lubrication and Maintenance Checks........................................722
		1000 Hour Lubrication and Maintenance Checks.......................................723
		2500 Hour Lubrication and Maintenance Checks.......................................724
		5000 Hour Lubrication and Maintenance Checks.......................................725
		10,000 Hour Lubrication and Maintenance Checks.....................................725
	Automatic Lubrication System...........................................................727
		General Description................................................................727
		System Components..................................................................729
		System Operation...................................................................730
			Injector Operation.............................................................732
		General Instructions...............................................................733
		System Checkout....................................................................736
			Pump Rebuild...................................................................737
			System Troubleshooting Chart...................................................740
		Preventative Maintenance Procedures................................................743
	Motorized Wheel Maintenance Schedule...................................................745
ALPHABETICAL INDEX.........................................................................749
SYSTEM SCHEMATICS..........................................................................753
	HH353 HYDRAULIC SCHEMATIC..............................................................755
	HH354 BRAKE SCHEMATIC..................................................................756
	ES0600.................................................................................757
		ES0601 INDEX AND SYMBOLS...........................................................757
		ES0602 CIRCUIT NUMBER LOCATION.....................................................758
		ES0603 COMPONENT LOCATOR...........................................................759
		ES0604 COMPONENT LOCATOR...........................................................760
		ES0605 G.E. FAULT CODES............................................................761
		ES0606 G.E. FAULT CODES............................................................762
		ES0607 POWER DISTRIBUTION - 24V....................................................763
		ES0608 POWER 18 ELEMENT 3 STEP RETARDING...........................................764
		ES0609 POWER 18 ELEMENT 3 STEP RETARDING...........................................765
		ES0610 POWER 20 ELEMENT 7 STEP RETARDING...........................................766
		ES0611 DRIVE SYSTEM CONTROL CIRCUITS...............................................767
		ES0612 TWO DIGIT DISPLAY...........................................................768
		ES0613 G.E. ANALOG INPUTS..........................................................769
		ES0614 G.E. DIGITAL INPUTS, AUTO LUBE CONTROL......................................770
		ES0615 REAR TAIL LIGHTS, DIMMER CONTROL............................................771
		ES0616 5 MINUTE IDLE, SPARE WIRES..................................................772
		ES0617 WINDOWS, RADIO, GAUGES......................................................773
		ES0618 CONTACTOR FEEDBACK..........................................................774
		ES0619 CONTACTOR COILS.............................................................775
		ES0620 MACHINE CONTROL CIRCUITS....................................................776
		ES0621 ACCELERATOR, RETARD PEDALS..................................................777
		ES0622 HYDRAULIC CONTROLS, ALARMS..................................................778
		ES0623 HEATER/AC, WINDSHIELD WIPER CONTROLS........................................779
		ES0624 LIGHT CONTROL CIRCUITS......................................................780
		ES0625 INSTRUMENT LIGHTS, DIAGNOSTIC PORTS.........................................781
		ES0626 MOD. MINING DISPATCH........................................................782
		ES0627 CUMMINS QSK60 ENGINE........................................................783
		ES0628 CUMMINS QSK60 ENGINE........................................................784
		ES0629 4000 DDEC ENGINE............................................................785

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]