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KOMATSU 830E DUMP TRUCK Shop Repair Manual SERIAL NUMBERS A30816 & UP – PDF DOWNLOAD
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KOMATSU 830E DUMP TRUCK Shop Repair Manual
SERIAL NUMBERS:A30816 & UP
PUBLICATION NUMBER:CEBM016701
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Description
KOMATSU 830E DUMP TRUCK Shop Repair Manual SERIAL NUMBERS A30816 & UP
KOMATSU 830E DUMP TRUCK SHOP REPAIR MANUAL SERIAL NUMBERS A30816 & UP – PDF DOWNLOAD:
SCREENSHOOTS OF THE MANUAL:
DESCRIPTION:
KOMATSU 830E DUMP TRUCK Shop Repair Manual SERIAL NUMBERS A30816 & UP
- 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.
- 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 Repair Manual SERIAL NUMBERS A30816 & UP
MAIN MENU............................................................................................................... 0 COVER................................................................................................................... 1 FOREWORD................................................................................................................ 5 TABLE OF CONTENTS....................................................................................................... 7 GENERAL INFORMATION..................................................................................................... 9 MAJOR COMPONENT DESCRIPTION......................................................................................... 11 SPECIFICATIONS.................................................................................................. 13 GENERAL SAFETY...................................................................................................... 15 SAFETY RULES.................................................................................................... 15 SAFETY FEATURES................................................................................................. 15 CLOTHING AND PERSONAL PROTECTIVE ITEMS.......................................................................... 15 UNAUTHORIZED MODIFICATION....................................................................................... 15 LEAVING THE OPERATOR'S SEAT..................................................................................... 16 MOUNTING AND DISMOUNTING........................................................................................ 16 FIRE PREVENTION FOR FUEL AND OIL................................................................................ 16 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES.................................................................. 17 ASBESTOS DUST HAZARD PREVENTION................................................................................. 17 PREVENTION OF INJURY BY WORK EQUIPMENT.......................................................................... 17 FIRE EXTINGUISHER AND FIRST AID KIT............................................................................. 17 PRECAUTIONS WHEN USING ROPS..................................................................................... 18 PRECAUTIONS FOR ATTACHMENTS..................................................................................... 18 PRECAUTIONS ON STARTING MACHINE................................................................................. 18 PRECAUTIONS DURING OPERATION.................................................................................... 19 SAFETY IS THINKING AHEAD.................................................................................... 19 SAFETY AT WORKSITE.......................................................................................... 19 FIRE PREVENTION............................................................................................. 19 PREPARING FOR OPERATION..................................................................................... 19 VENTILATION FOR ENCLOSED AREAS.............................................................................. 19 IN OPERATOR'S CAB - BEFORE STARTING ENGINE.................................................................. 20 KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN..................................................................... 20 OPERATING THE MACHINE....................................................................................... 20 WHEN STARTING ENGINE.................................................................................... 20 Truck Operation - General............................................................................... 20 CHECK WHEN TRAVELING IN REVERSE......................................................................... 21 TRAVELING............................................................................................... 21 TRAVELING ON SLOPES..................................................................................... 22 ENSURE GOOD VISIBILITY.................................................................................. 22 OPERATE CAREFULLY ON SNOW............................................................................... 22 AVOID DAMAGE TO DUMP BODY............................................................................... 22 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.................................................................. 22 WHEN DUMPING............................................................................................ 23 WORKING ON LOOSE GROUND................................................................................. 23 WHEN LOADING............................................................................................ 23 PARKING THE MACHINE..................................................................................... 23 TOWING...................................................................................................... 23 WHEN TOWING, FIX WIRE TO HOOK........................................................................... 23 BATTERY..................................................................................................... 24 BATTERY HAZARD PREVENTION............................................................................... 24 STARTING WITH BOOSTER CABLES............................................................................ 24 PRECAUTIONS FOR MAINTENANCE..................................................................................... 25 BEFORE CARRYING OUT MAINTENANCE............................................................................. 25 WARNING TAG............................................................................................. 25 PROPER TOOLS............................................................................................ 25 STOPPING THE ENGINE BEFORE SERVICE...................................................................... 25 SECURING THE DUMP BODY.................................................................................. 25 DURING MAINTENANCE.......................................................................................... 26 PERSONNEL............................................................................................... 26 ATTACHMENTS............................................................................................. 26 WORK UNDER THE MACHINE.................................................................................. 26 KEEP THE MACHINE CLEAN.................................................................................. 26 RULES TO FOLLOW WHEN ADDING FUEL OR OIL................................................................. 26 RADIATOR WATER LEVEL.................................................................................... 27 USE OF LIGHTING......................................................................................... 27 PRECAUTIONS WITH BATTERY................................................................................ 27 HANDLING HIGH-PRESSURE HOSES............................................................................ 27 PRECAUTIONS WITH HIGH PRESSURE OIL...................................................................... 27 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE.......................... 28 ROTATING FAN AND BELT................................................................................... 28 WASTE MATERIALS......................................................................................... 28 TIRES....................................................................................................... 29 HANDLING TIRES.......................................................................................... 29 STORING TIRES AFTER REMOVAL............................................................................. 29 ADDITIONAL JOB SITE RULES....................................................................................... 30 WHEN REPAIRS ARE NECESSARY...................................................................................... 31 OPERATING INSTRUCTIONS.......................................................................................... 33 PREPARING FOR OPERATION..................................................................................... 33 Safety Is Thinking Ahead................................................................................ 33 WALK AROUND INSPECTION...................................................................................... 33 ENGINE START-UP SAFETY PRACTICES............................................................................ 36 AFTER ENGINE HAS STARTED.................................................................................... 37 MACHINE OPERATION SAFETY PRECAUTIONS........................................................................ 38 HAULING..................................................................................................... 38 STARTING ON A GRADE WITH A LOADED TRUCK..................................................................... 39 PASSING..................................................................................................... 39 LOADING..................................................................................................... 40 DUMPING..................................................................................................... 40 To Raise dump body:..................................................................................... 40 To Lower Body........................................................................................... 41 To Lower Body........................................................................................... 41 DYNAMIC RETARDING OPERATION................................................................................. 42 SUDDEN LOSS OF ENGINE POWER................................................................................. 42 SAFE PARKING PROCEDURES..................................................................................... 43 ENGINE SHUTDOWN PROCEDURE................................................................................... 43 DELAYED ENGINE SHUTDOWN PROCEDURE........................................................................... 44 EMERGENCY STEERING SYSTEM................................................................................... 45 Operation............................................................................................... 45 Testing................................................................................................. 45 DISABLED TRUCK DUMPING PROCEDURE............................................................................ 46 Hookup.................................................................................................. 46 Raising the Body........................................................................................ 46 Lowering the Body....................................................................................... 46 TOWING...................................................................................................... 47 WARNINGS AND CAUTIONS............................................................................................... 49 STANDARD CHARTS AND TABLES.......................................................................................... 57 STORAGE AND IDLE MACHINE PREPARATION................................................................................ 63 SHORT TERM IDLE PERIODS......................................................................................... 63 PREPARATION FOR STORAGE......................................................................................... 64 REMOVAL FROM STORAGE........................................................................................ 65 RECONDITIONING AN IDLE VEHICLE.................................................................................. 67 ENGINE OPERATION................................................................................................ 70 AFTER ENGINE HAS STARTED........................................................................................ 71 ENGINE STORAGE-CUMMINS.......................................................................................... 72 Engine Storage-(Short Term)..................................................................................... 72 Prepare the Engine for Short Term Storage....................................................................... 72 Remove the Engine from Short Term Storage....................................................................... 72 Engine Storage- (Long Term)..................................................................................... 73 6 Months to 24 Months....................................................................................... 73 Prepare the Engine for Long Term Storage........................................................................ 73 Remove the Engine from Long Term Storage........................................................................ 73 ENGINE STORAGE - DETROIT DIESEL................................................................................. 74 Preparing Engine For Storage.................................................................................... 74 Temporary Storage (30 Days Or Less)............................................................................. 74 Extended Storage (more Than 30 Days)............................................................................ 74 PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE................................. 76 ELECTRIC DRIVE TRUCKS........................................................................................... 77 Storage Instructions and Procedures............................................................................. 77 Placing Equipment Into Storage.................................................................................. 77 When Storing A Truck That Is Operational........................................................................ 77 When Storing A Truck That Is Not Operational.................................................................... 78 When Storing A Major Component.................................................................................. 78 Periodic Inspections............................................................................................ 79 Placing Equipment Into Service After Storage.................................................................... 79 When A Truck Is Operational................................................................................. 79 When A Truck Is Not Operational............................................................................. 79 For The First Hour.......................................................................................... 80 PRESERVATION AND STORAGE ALLISON TRANSMISSION................................................................... 81 Storage, New Transmission................................................................................... 81 Storage, One Year -- Without Oil............................................................................ 81 Storage, One Year With Oil (normally in a vehicle chassis).................................................. 81 Restoring Transmission to Service........................................................................... 81 STRUCTURES.............................................................................................................. 83 STRUCTURAL COMPONENTS............................................................................................... 85 Ladders......................................................................................................... 85 Removal..................................................................................................... 86 Installation................................................................................................ 86 RIGHT HAND DECK................................................................................................. 86 Removal..................................................................................................... 86 Installation................................................................................................ 86 CENTER AND LEFT HAND DECK COMPONENTS............................................................................ 87 FUEL TANK....................................................................................................... 88 Removal..................................................................................................... 88 Installation................................................................................................ 88 LADDERS..................................................................................................... 85 DUMP BODY........................................................................................................... 89 Removal......................................................................................................... 89 Installation.................................................................................................... 90 BODY PADS....................................................................................................... 91 Adjustment.................................................................................................. 92 BODY GUIDE...................................................................................................... 92 BODY-UP RETENTION CABLE......................................................................................... 92 BODY POSITION INDICATOR......................................................................................... 93 ROCK EJECTORS................................................................................................... 93 Inspection.................................................................................................. 93 HOIST LIMIT SWITCH.............................................................................................. 93 BODY UP SWITCH.................................................................................................. 93 ENGINE.................................................................................................................. 95 POWER MODULE........................................................................................................ 97 PREPARATION..................................................................................................... 97 Removal..................................................................................................... 97 Installation................................................................................................101 COOLING SYSTEM......................................................................................................103 COOLING SYSTEM DESCRIPTION......................................................................................103 RADIATOR........................................................................................................104 Removal.....................................................................................................104 Service.........................................................................................................106 Installation................................................................................................106 RADIATOR FILLING PROCEDURE..................................................................................106 POWER TRAIN.........................................................................................................107 ALTERNATOR REMOVAL PROCEDURE....................................................................................107 Removal (Komatsu SSDA16V160 or SDA16V160 Engine)............................................................107 ENGINE/ALTERNATOR MATING........................................................................................109 General Instructions........................................................................................109 MEASURING PROCEDURE.........................................................................................109 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine...............................................111 ENGINE..........................................................................................................112 Removal.....................................................................................................112 Service.....................................................................................................112 Installation................................................................................................112 AIR FILTRATION SYSTEM...............................................................................................113 AIR CLEANER.....................................................................................................113 Operation...................................................................................................113 General Service Information.................................................................................113 MAIN FILTER ELEMENT.............................................................................................113 Removal.....................................................................................................113 Installation................................................................................................114 SAFETY FILTER ELEMENT...........................................................................................115 Removal.....................................................................................................115 Installation................................................................................................115 AIR INTAKE TROUBLESHOOTING......................................................................................115 AIR CLEANER ASSEMBLY CLEANING...................................................................................115 Main Filter Cleaning........................................................................................115 Precleaner Section Cleaning.................................................................................116 FAN CLUTCH..........................................................................................................119 REMOVAL & INSTALLATION TOOLING..................................................................................119 FAN CLUTCH - DISASSEMBLY........................................................................................122 CLEANING AND INSPECTION.........................................................................................132 ASSEMBLY - FAN CLUTCH...........................................................................................136 TEST PROCEDURE..................................................................................................150 ELECTRICAL SYSTEM (24VDC)...............................................................................................151 24VDC ELECTRIC SUPPLY SYSTEM........................................................................................153 ELECTRICAL SYSTEM DESCRIPTION...................................................................................153 BATTERY.....................................................................................................153 Maintenance and Service.....................................................................................153 Troubleshooting.................................................................................................153 BATTERY CHARGING SYSTEM (Niehoff)...............................................................................155 General Description.............................................................................................155 TROUBLESHOOTING PROCEDURES (On-Truck)...........................................................................155 Preliminary Checks..........................................................................................156 Test Setup..................................................................................................156 Test Procedure..............................................................................................156 Regulator Bypass Test.......................................................................................157 ON VEHICLE TROUBLESHOOTING GUIDE - SELF ENERGIZED ALTERNATOR....................................................158 ALTERNATOR ELECTRICAL CONDITION - Low Voltage - High Voltage - No Voltage...................................158 PRELIMINARY PROCEDURES......................................................................................158 LOW VOLTAGE OUTPUT......................................................................................158 HIGH VOLTAGE OUTPUT.....................................................................................158 NO VOLTAGE OUTPUT.......................................................................................158 TOOLS AND EQUIPMENT:........................................................................................158 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:............................................................158 Low Maintenance Types:..................................................................................158 Maintenance Free types:.................................................................................159 High-Cycle Maintenance Free Types:......................................................................159 DEFINITIONS.................................................................................................159 ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized.........................................................160 NO ALTERNATOR OUTPUT........................................................................................160 STATIC TEST - ENGINE OFF, KEY ON, BATTERY SWITCH ON.....................................................160 GO TO ALTERNATOR”.......................................................................................160 GO TO “R” TERMINAL ON ALTERNATOR........................................................................160 RE-TEST CHARGING CIRCUIT FOR OPERATION with ENGINE RUNNING..............................................160 GO TO REGULATOR (IF REQUIRED)...........................................................................161 GO TO REGULATOR CONNECTOR ON ALTERNATOR.................................................................161 24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE)...............................................................162 OPERATION...............................................................................................162 Pressure Switch.........................................................................................163 Check Valve.............................................................................................163 Timer Solenoid..........................................................................................163 MAINTENANCE.................................................................................................163 Prelube System Operation Checks.........................................................................163 Check Valve.............................................................................................163 Timer Solenoid..........................................................................................163 Troubleshooting Prelube Starter Circuit.........................................................................164 24 VDC ELECTRIC START SYSTEM....................................................................................166 CRANKING MOTORS.............................................................................................166 OPERATION...............................................................................................166 Removal.................................................................................................166 Installation............................................................................................166 CRANKING MOTOR TROUBLESHOOTING..............................................................................167 Preliminary Inspection..................................................................................167 No-Load Test............................................................................................167 Interpreting Results of Tests...........................................................................167 Disassembly.............................................................................................168 Cleaning and Inspection.................................................................................170 Armature Servicing......................................................................................170 Field Coil Checks.......................................................................................170 Field Coil Removal......................................................................................170 Solenoid Checks.............................................................................................171 Test....................................................................................................171 Assembly................................................................................................172 Bearing Replacement:....................................................................................172 Motor Assembly:.........................................................................................172 Pinion Clearance........................................................................................173 MAGNETIC SWITCH.........................................................................................173 Installation............................................................................................173 Coil Test...............................................................................................174 24 VDC ELECTRICAL SYSTEM COMPONENTS.................................................................................175 PASSENGER SEAT BASE COMPARTMENT.................................................................................175 COMPONENTS......................................................................................................175 TAIL LIGHT RESISTOR DIODE ASSEMBLIES........................................................................175 INCLINOMETER................................................................................................175 BRAKE WARNING BUZZER (BWB)..................................................................................175 LUBRICATION SYSTEM TIMER....................................................................................175 5 MINUTE IDLE TIMER COMPONENTS..............................................................................175 5 Minute Idle Timer.........................................................................................177 5 Minute Idle Relay.........................................................................................177 5 Minute Idle Contactor.....................................................................................177 5 MINUTE IDLE CIRCUIT TEST..................................................................................177 DATA STORE SWITCH...........................................................................................177 KOMATSU ENGINE QUANTUM CONNECTOR............................................................................177 KOMATSU ENGINE CENSE CONNECTOR..............................................................................177 STATEX III PROPULSION SYSTEM DIAGNOSTIC CONNECTOR...........................................................177 SPARE CONNECTOR LOCATION....................................................................................177 ALARM INDICATING DEVICE (AID) SYSTEM........................................................................178 Diode Matrix (Without Sound)................................................................................178 Diode Matrix (With Sound)...................................................................................178 Hot Switch Inverter.........................................................................................179 Hot Switch Inverter Card (Slot 4) (Not Used)................................................................179 Temperature.................................................................................................179 Oil Level...................................................................................................179 Temperature and Latch.......................................................................................179 Coolant Level/Flasher.......................................................................................179 Lamp Test...................................................................................................179 BATTERY EQUALIZER BOX...........................................................................................180 Troubleshooting.................................................................................................180 BODY-UP SWITCH..................................................................................................181 Adjustment..................................................................................................181 Service.....................................................................................................181 HOIST LIMIT SWITCH..............................................................................................181 Adjustment..................................................................................................181 Service.....................................................................................................181 24 VOLT RELAY AND DIODE BOARDS..................................................................................182 RELAY BOARDS................................................................................................182 Description.................................................................................................182 SERVICE.....................................................................................................183 To replace a relay:.........................................................................................183 To replace a circuit breaker:...............................................................................183 To replace a circuit panel card.............................................................................184 RELAY BOARD COMPONENTS......................................................................................184 DIODE BOARD 1...............................................................................................187 Diode Testing...............................................................................................187 CIRCUIT BREAKERS................................................................................................187 VEHICLE HEALTH MONITORING SYSTEM (VHMS).............................................................................189 VHMS BASIC FEATURES.............................................................................................189 Gather Data.................................................................................................189 Convert and Record Data.....................................................................................190 Communicate Data to Off-Board Systems.......................................................................190 USING THE VHMS SYSTEM...........................................................................................191 Turning the VHMS System ON..................................................................................191 Normal VHMS Operation.......................................................................................192 Turning the VHMS System OFF.................................................................................192 Downloading from the VHMS controller........................................................................192 VHMS DATA ITEMS.................................................................................................193 Fault Codes.................................................................................................193 Machine History.............................................................................................193 VHMS History................................................................................................193 Snapshots...................................................................................................193 Manual Snapshots............................................................................................195 Trends......................................................................................................195 Histogram (Load Map) Data...................................................................................197 Haul Cycle Data.............................................................................................197 Alarm and Snapshot Triggers.................................................................................199 Satellite Features..........................................................................................201 VHMS DIAGNOSTIC FEATURES........................................................................................201 Fault History...............................................................................................201 VHMS LED Digits.............................................................................................201 VHMS COMPONENTS.................................................................................................202 VHMS Controller.............................................................................................202 Removal.....................................................................................................202 Installation................................................................................................203 OrbComm Controller..........................................................................................203 Removal.....................................................................................................203 Installation................................................................................................204 Interface Module............................................................................................204 Removal.....................................................................................................205 Installation................................................................................................205 Temperature Sensors.........................................................................................206 Pressure Sensors............................................................................................207 VHMS SOFTWARE.......................................................................................................209 NECESSARY SOFTWARE..............................................................................................209 NECESSARY TOOLS.................................................................................................209 VHMS TOOL BOX INSTALLATION......................................................................................210 VHMS SETTING TOOL INSTALLATION..................................................................................210 VHMS INITIALIZATION PROCEDURE...................................................................................210 Preliminary Checks..........................................................................................210 Initialization Steps........................................................................................211 Select Operation............................................................................................211 VHMS Setting Function.......................................................................................211 Machine Information Setting(1)..............................................................................211 Machine Information Setting(2)..............................................................................211 Date & Time Setting.........................................................................................212 GCC Setting.................................................................................................212 Setting Summary.............................................................................................212 VHMS SNAPSHOT PROCEDURE.........................................................................................213 VHMS DOWNLOAD...................................................................................................213 VHMS FTP UPLOAD.................................................................................................214 LOCATION OF DOWNLOAD FILES......................................................................................215 INSTALLING FLASHBURN PROGRAM....................................................................................216 INSTALLING APPLICATION CODE INTO INTERFACE MODULE...............................................................216 INSTALLING VHMS WATCHER PROGRAM.................................................................................217 INSTALLING VHMS WATCHER DATA FILES..............................................................................217 WHEN REPLACING A VHMS CONTROLLER................................................................................217 To Set: Date & Time; Satellite; Payload Meter...............................................................220 Review Setting Information..................................................................................221 VHMS CHECKOUT & TROUBLESHOOTING.....................................................................................223 VHMS CHECKOUT PROCEDURE.........................................................................................223 General.....................................................................................................223 Structure and Purpose.......................................................................................224 Necessary Equipment:........................................................................................224 VHMS SYSTEM CHECKOUT............................................................................................224 Preliminary.................................................................................................224 Checking Inputs To The Interface Module.....................................................................225 Checking Outputs From The Interface Module..................................................................228 VHMS CONTROLLER CHECKOUT........................................................................................228 TROUBLESHOOTING.................................................................................................229 Communications Networks.....................................................................................229 Coaxial Cable...............................................................................................229 VHMS COMPONENTS.................................................................................................230 VHMS Controller.............................................................................................230 OrbComm Controller..........................................................................................231 Interface Module............................................................................................231 FAULT CODES.....................................................................................................232 Fault History...............................................................................................232 VHMS LED Display Fault Codes................................................................................233 Chassis Fault Codes.........................................................................................234 Engine Fault Codes..........................................................................................237 FAULT TREE ANALYSIS.............................................................................................243 Unable to connect to VHMS from laptop PC....................................................................243 Flashing Error Code N4-23 (PLM III Communications Fault)....................................................244 Flashing Error Code N4-22 (Engine Communications Fault).....................................................245 No Data Received By WebCARE.................................................................................246 Coaxial Cable Troubleshooting...............................................................................247 VHMS FORMS..........................................................................................................249 VHMS INITIALIZATION CHECK LIST..................................................................................249 VHMS DATA DOWNLOAD..............................................................................................250 VHMS INITIALIZATION FORM........................................................................................250 VHMS INITIALIZATION CHECK LIST..................................................................................251 VHMS INITIALIZATION FORM........................................................................................253 ELECTRICAL PROPULSION COMPONENTS........................................................................................255 ELECTRICAL PROPULSION COMPONENTS....................................................................................257 ELECTRICAL PROPULSION COMPONENTS................................................................................261 GENERAL SYSTEM DESCRIPTION..................................................................................261 CONTROL SYSTEM..............................................................................................261 System Operation........................................................................................262 FL275 Panel.............................................................................................263 CARD REPLACEMENT............................................................................................264 Removal.................................................................................................264 Installation............................................................................................264 Card Repair.............................................................................................264 Panel Wiring............................................................................................264 COMPUTER DESCRIPTION........................................................................................265 Microprocessor..........................................................................................265 Download Capability.....................................................................................265 SOFTWARE....................................................................................................265 Base Monitor Program....................................................................................265 Runtime Monitor Program - OBJ Running Code..............................................................265 Configuration Software - CFG............................................................................266 PTU - Portable Test Unit Code...........................................................................266 System Regulation.......................................................................................266 Propulsion..............................................................................................267 Retarding...............................................................................................267 TWO-DIGIT DISPLAY PANEL.....................................................................................268 The Coded Number........................................................................................268 Events..................................................................................................268 Frames..................................................................................................269 Windows.................................................................................................269 System Categories.......................................................................................269 Limits On Resetting Faults..............................................................................269 NA Faults...............................................................................................270 Event Sequence..........................................................................................270 Resetting Events........................................................................................270 Event Descriptions......................................................................................270 Subcode Descriptions....................................................................................270 2-DIGIT DISPLAY PANEL SUBCODES..............................................................................278 PORTABLE TEST UNIT (PTU)........................................................................................281 DESCRIPTION.................................................................................................281 Operational Hints.......................................................................................281 SOFTWARE INSTALLATION PREPARATION...........................................................................282 HARD DISK SPACE REQUIREMENTS................................................................................282 SOFTWARE INSTALLATION ON PTU................................................................................282 PTU/Truck Communication Problems........................................................................283 THE MAIN MENU...............................................................................................284 Quit Menu...............................................................................................284 PTU Talk To Truck.......................................................................................284 View PTU Saved Files....................................................................................284 List Stat Data Files....................................................................................284 Truck Setup (CFG).......................................................................................284 Select Truck Setup......................................................................................284 Update CFG Version......................................................................................284 Change PTU Password.....................................................................................284 CONFIGURATION (CFG) FILE CONVERSION.........................................................................286 Conversion Procedure....................................................................................286 Convert Old CFG files for New software..................................................................287 STATEX CONFIGURATION FILES..................................................................................290 0) Source Directory: . . ...............................................................................290 1) Select A Truck Configuration . . ....................................................................291 2) View Truck Configuration: Data Curves . . ...........................................................292 3) Change/View Serial and Model Numbers . . ............................................................293 4) View Options . . ....................................................................................293 5) Change/View Truck Specifics . . .....................................................................295 6) Change/View Overspeeds . . ..........................................................................297 7) Save a Truck Configuration, filename: . . ...........................................................298 8) Save Directory: . . .................................................................................299 CHANGE PTU PASSWORD.........................................................................................300 PROGRAMMING THE TRUCK.......................................................................................301 Connect PTU to the Truck................................................................................301 Select Configuration File...............................................................................301 Activate The PTU Mode...................................................................................301 Check Object Code Version...............................................................................302 Download Configuration Files............................................................................303 Date And Time...........................................................................................304 Event Data..............................................................................................305 Statistical Data........................................................................................307 View Counters...........................................................................................307 View Profiles...........................................................................................307 Upload Statistical Data To A File.......................................................................307 Statistical Data Codes - Counters.......................................................................308 STATISTICAL DATA CODES - COUNTERS...........................................................................309 STATISTICAL DATA CODES - PROFILES...........................................................................314 TRUCK SPECIFIC INFORMATION..................................................................................318 Temporary Truck Settings................................................................................319 MISCELLANEOUS FEATURES......................................................................................320 Saving Data.............................................................................................320 PTU Abbreviations.......................................................................................321 Other Menu Selections...................................................................................321 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..................................................................322 ALTERNATOR..................................................................................................322 ELECTRIC WHEEL MOTORS.......................................................................................322 RETARDING GRIDS.............................................................................................322 ELECTRONIC ACCELERATOR AND RETARD PEDALS....................................................................322 Removal.................................................................................................322 Installation............................................................................................322 Disassembly.............................................................................................323 Reassembly..............................................................................................323 COOLING BLOWER WARNING SYSTEM...............................................................................323 Operation...............................................................................................323 Test....................................................................................................323 Removal.................................................................................................324 Installation............................................................................................324 ELECTRICAL CONTROL CABINET......................................................................................325 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS..........................................................330 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III..............................................................331 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.....................................................................333 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.................................................................337 GENERAL INFORMATION.........................................................................................337 COMMUNICATIONS PORT CHECK...................................................................................338 PTU Hookup..............................................................................................338 4.0 SEQUENCE TESTS - (ENGINE NOT ON)........................................................................339 Preparation and Setup...................................................................................339 CONTROL SYSTEM SELF-TEST................................................................................340 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT................................................................340 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT..................................................................341 PTU Setup...........................................................................................341 4.3 REVERSER AND PROPULSION CONTACTORS CHECK............................................................342 4.4 NOT USED............................................................................................343 4.5 RETARD CONTACTORS OPERATION CHECK...................................................................343 4.6 GROUND FAULT SENSING CHECK..........................................................................343 4.7 GROUND FAULT IN RETARD OPERATION CHECK..............................................................344 4.8 OVERRIDE OPERATION CHECK............................................................................344 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK...................................................................345 4.10 OVERSPEED RETARD OPERATION CHECK...................................................................345 4.11 HOIST INTERLOCK OPERATION CHECK....................................................................346 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK...........................................................346 Return to Main Menu.................................................................................346 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL....................................................347 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.......................................................347 5.2 DIGITAL INPUT CHECKS................................................................................348 5.3 DIGITAL OUTPUT CHECKS...............................................................................349 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL............................................................353 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU............................................................353 6.2 ANALOG INPUT CHECKS.................................................................................354 6.3 FREQUENCY INPUT CHECKS..............................................................................358 Return to Main Menu.................................................................................359 7.0 SPEED EVENT CHECKS......................................................................................359 Preparation and Setup...................................................................................359 Setup PTU...............................................................................................359 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK.............................................360 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK..................................360 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK.................................360 7.4 OTHER SPEED EVENTS CHECKS...........................................................................360 Return to Main Menu.................................................................................360 8.0 RETARD SPEED CONTROL SYSTEM CHECK.......................................................................361 Preparation and Setup...................................................................................361 Setup PTU...............................................................................................361 8.1 OVERSPEED PICKUP AND DROPOUT CHECK..................................................................361 8.2 RETARD POT MAXIMUM SETTING CHECK....................................................................361 8.3 RETARD POT MINIMUM SETTING CHECK....................................................................361 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL..................................................362 Return to Main Menu.................................................................................362 9.0 LOAD TEST USING TRUCK RETARD GRIDS......................................................................362 Setup and Preparation...................................................................................362 PTU Setup...............................................................................................362 9.1 LOAD TEST...........................................................................................363 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING.................................................................363 Setup PTU...............................................................................................363 10.1 RETARD CHECK.......................................................................................364 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT............................................................365 11.1 BRAKE SYSTEM INTERLOCKS CHECK......................................................................365 Preparation.........................................................................................365 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT.............................................................365 11.3 SYNC TRANSFORMER CHECKOUT..........................................................................366 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT.........................................................366 11.5 BATTERY BOOST ADJUSTMENT...........................................................................366 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST........................................................366 11.7 MOTOR ROTATION TEST................................................................................367 11.8 GROUND FAULT CHECKS................................................................................367 12.0 MISCELLANEOUS CHARTS...................................................................................368 12.1 WHEEL MOTOR GEAR RATIOS............................................................................368 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS.....................................................................369 12.3 ENGINE OPTIONS.....................................................................................370 DRIVE AXLE, SPINDLE AND WHEELS..........................................................................................371 TIRES AND RIMS......................................................................................................373 FRONT TIRES AND RIMS............................................................................................373 Removal.....................................................................................................373 Installation................................................................................................374 REAR TIRES AND RIMS.............................................................................................375 Removal.....................................................................................................375 Installation................................................................................................376 RIM.........................................................................................................377 Tire Removal................................................................................................377 RIM AND TIRE PREPARATION........................................................................................377 LUBRICANTS......................................................................................................378 TIRE INSTALLATION...............................................................................................378 FRONT WHEEL HUB AND SPINDLE.........................................................................................381 WHEEL HUB AND SPINDLE ASSEMBLY..................................................................................381 Removal.....................................................................................................381 Spindle Pusher Tool Usage...................................................................................382 Installation................................................................................................383 Disassembly.................................................................................................385 Cleaning and Inspection.....................................................................................385 Assembly....................................................................................................386 Wheel Bearing Adjustment (Tire Removed).....................................................................388 Wheel Bearing Adjustment (Tire mounted).....................................................................388 STEERING CYLINDERS AND TIE ROD..................................................................................390 Spherical Bearing Wear Limits...............................................................................390 Removal.....................................................................................................391 Installation................................................................................................391 Bearing Replacement.........................................................................................391 TOE-IN ADJUSTMENT...............................................................................................393 REAR AXLE HOUSING ATTACHMENT........................................................................................395 PIVOT PIN.......................................................................................................395 Removal.....................................................................................................395 Installation................................................................................................395 PIVOT EYE BEARING...............................................................................................396 Disassembly.................................................................................................396 Assembly....................................................................................................396 PIVOT EYE REPAIR................................................................................................397 Removal.....................................................................................................397 Disassembly.................................................................................................397 Assembly....................................................................................................397 Installation................................................................................................397 ANTI-SWAY BAR...................................................................................................398 Removal.....................................................................................................398 Installation................................................................................................398 Disassembly.................................................................................................398 Cleaning and Inspection.....................................................................................398 Assembly....................................................................................................398 REAR AXLE HOUSING...................................................................................................399 REAR AXLE HOUSING...............................................................................................399 Removal.....................................................................................................399 Installation................................................................................................399 WHEEL MOTOR.....................................................................................................399 Removal.....................................................................................................399 Cleaning and Inspection.....................................................................................400 Installation................................................................................................400 Maximum Cap Screw Usage.....................................................................................400 SUSPENSIONS.............................................................................................................401 FRONT SUSPENSION....................................................................................................403 Removal.........................................................................................................403 Installation....................................................................................................404 MAXIMUM CAP SCREW USAGE.........................................................................................405 “TURN-OF-THE-NUT” Tightening Procedure..........................................................................406 MINOR REPAIR ONLY (Lower Bearing Structure & Seals).............................................................407 Bearing Structure Removal...................................................................................407 Bearing Structure Installation..............................................................................407 MAJOR SUSPENSION REBUILD........................................................................................408 Disassembly.................................................................................................408 Assembly....................................................................................................409 PRESSURE TEST...................................................................................................410 REAR SUSPENSIONS....................................................................................................411 Removal.........................................................................................................411 Installation....................................................................................................413 Disassembly.....................................................................................................415 Cleaning and Inspection.........................................................................................415 Assembly........................................................................................................415 PRESSURE TEST...................................................................................................416 OILING AND CHARGING PROCEDURE.......................................................................................417 GENERAL.........................................................................................................417 EQUIPMENT LIST..................................................................................................417 HYDRAIR® CHARGING KIT...........................................................................................417 Installation of Charging Kit................................................................................417 Removal of Charging Kit.....................................................................................418 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS...............................................................418 FRONT SUSPENSION................................................................................................419 Front Suspension Oiling.....................................................................................419 Front Suspension Nitrogen Charging..........................................................................420 REAR SUSPENSION.................................................................................................421 Rear Suspension Oiling......................................................................................421 Rear Suspension Nitrogen Charging...........................................................................422 OIL AND NITROGEN SPECIFICATIONS CHART...........................................................................424 BRAKE SYSTEM............................................................................................................425 BRAKE CIRCUIT.......................................................................................................427 SERVICE BRAKE CIRCUIT OPERATION.................................................................................427 SECONDARY BRAKING AND AUTOMATIC APPLY...........................................................................429 PARKING BRAKE CIRCUIT...........................................................................................429 Normal Operation (key switch on, engine running)............................................................429 BRAKE LOCK CIRCUIT..............................................................................................430 WARNING CIRCUIT.................................................................................................430 BRAKE CIRCUIT COMPONENT SERVICE.....................................................................................433 BRAKE VALVE.....................................................................................................433 Rebuild Criteria............................................................................................433 Removal.....................................................................................................433 DISASSEMBLY.....................................................................................................436 Cleaning and Inspection.....................................................................................438 ASSEMBLY........................................................................................................438 Actuator Base Threaded Inserts..............................................................................438 Boot and Cap................................................................................................438 Valve Body Seal Installation................................................................................439 Regulator Sleeve O-Ring Installation........................................................................439 Actuator Plunger O-ring Installation........................................................................439 Assembly of Valve...........................................................................................440 DIFFERENTIAL PRESSURE SWITCH....................................................................................441 Disassembly.................................................................................................441 Cleaning and Inspection.....................................................................................441 Assembly....................................................................................................441 VALVE BENCH TEST AND ADJUSTMENT.................................................................................442 Test Set Up Procedure.......................................................................................443 Brake Valve Output Pressure Adjustment......................................................................443 Differential Pressure Switch Test...........................................................................443 Final Test and Adjustment...................................................................................444 Installation Of Brake Pedal Actuator Assembly to Brake Valve................................................445 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal)............................446 Installation of Retard Pedal To Brake Pedal.................................................................446 HYDRAULIC BRAKE ACCUMULATORS....................................................................................447 Brake Accumulator Bleed Down Procedure......................................................................447 Removal.....................................................................................................447 Installation................................................................................................447 Disassembly.................................................................................................447 Cleaning and Inspection.....................................................................................448 Assembly....................................................................................................449 Charging Procedure..........................................................................................450 BRAKE MANIFOLD..................................................................................................451 Removal.....................................................................................................451 Removal.....................................................................................................451 Installation................................................................................................452 Disassembly.................................................................................................452 Cleaning and Inspection.....................................................................................452 Assembly....................................................................................................452 BRAKE CIRCUIT CHECK-OUT PROCEDURE...................................................................................453 EQUIPMENT REQUIRED..............................................................................................455 INITIAL SYSTEM SET-UP...........................................................................................456 PARKING BRAKE...................................................................................................456 BRAKE SYSTEM CHECK-OUT..........................................................................................456 Failure Modes Check-Out.........................................................................................457 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...................................................................459 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET...................................................463 KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET.......................................................464 ROCKWELL WHEEL SPEED FRONT DISC BRAKES..............................................................................465 BRAKE CALIPER...................................................................................................465 Caliper Removal.............................................................................................465 Installation................................................................................................466 Disassembly.................................................................................................467 Assembly....................................................................................................467 Cleaning and Inspection.....................................................................................468 BRAKE LINING....................................................................................................469 Replacement.................................................................................................469 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.........................................................470 SAFETY PRECAUTIONS..........................................................................................470 FRONT BRAKE CONDITIONING....................................................................................470 BRAKE BLEEDING PROCEDURES...................................................................................471 ROCKWELL ARMATURE SPEED REAR DISC BRAKES............................................................................473 REAR BRAKES.....................................................................................................473 CALIPER, DISC, AND PARKING BRAKE................................................................................473 Caliper, Disc, and Parking Brake Removal....................................................................473 Caliper, Disc, And Parking Brake Installation...............................................................474 CALIPER, DISC, & PARKING BRAKE REMOVAL [For trucks equipped with one-piece adapter (16, Figure 6-3A)].......476 Caliper, Disc, And Parking Brake Installation...............................................................477 CALIPER PISTON..................................................................................................478 Piston Assembly Removal.....................................................................................478 Inspection..................................................................................................478 Piston Assembly Installation................................................................................478 FUNCTIONAL TEST OF PISTON ASSEMBLY..........................................................................479 Return Spring Force.........................................................................................479 Built-In Clearance..........................................................................................479 Grip Force..................................................................................................480 Grip Force Measurement......................................................................................481 Spring Force Measurement....................................................................................482 Disassembly of Piston Assembly..............................................................................483 Assembly of Piston Assembly.................................................................................484 BENCH TEST..................................................................................................484 BRAKE LINING....................................................................................................485 Replacement.................................................................................................485 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE...............................................................488 General.....................................................................................................488 Safety Precautions..........................................................................................488 Rear Brake Conditioning.................................................................................489 BRAKE BLEEDING PROCEDURE................................................................................490 ROCKWELL DISC PARKING BRAKE.........................................................................................491 PARK BRAKE CALIPER..............................................................................................491 Removal.....................................................................................................491 Installation................................................................................................492 Parking Brake Adjustment....................................................................................492 Park Brake Caliper Disassembly..............................................................................494 Cleaning and Inspection.....................................................................................494 Park Brake Caliper Assembly.................................................................................495 PARK BRAKE LINING REPLACEMENT...................................................................................496 PARK BRAKE BURNISH PROCEDURE....................................................................................496 Lining Conditioning.........................................................................................496 BRAKE BLEEDING PROCEDURE........................................................................................496 HYDRAULIC SYSTEM........................................................................................................497 HYDRAULIC SYSTEM....................................................................................................499 HYDRAULIC SYSTEM OPERATION......................................................................................499 COMPONENT DESCRIPTION...........................................................................................500 HYDRAULIC SYSTEM COMPONENT REPAIR...................................................................................503 HOIST PUMP......................................................................................................503 Removal.....................................................................................................503 Installation................................................................................................504 Disassembly.................................................................................................505 INSPECTION OF PARTS.............................................................................................508 Assembly....................................................................................................509 HYDRAULIC TANK..................................................................................................514 Filling Instructions........................................................................................514 Removal.....................................................................................................514 Installation................................................................................................515 HYDRAULIC TANK STRAINERS........................................................................................515 Removal.....................................................................................................515 Inspect and Clean...........................................................................................515 Installation................................................................................................515 HYDRAULIC TANK BREATHERS........................................................................................516 HOIST CIRCUIT FILTERS...........................................................................................516 FILTER ELEMENT REPLACEMENT......................................................................................517 Removal.....................................................................................................517 INDICATOR SWITCH............................................................................................517 STEERING CIRCUIT....................................................................................................519 STEERING CIRCUIT OPERATION......................................................................................519 COMPONENT DESCRIPTION...........................................................................................520 STEERING CONTROL UNIT.......................................................................................520 FLOW AMPLIFIER..............................................................................................520 No Steer....................................................................................................522 Steering Left...............................................................................................524 Steering Right..............................................................................................526 No Steer, External Shock Load...............................................................................528 BLEED DOWN MANIFOLD.........................................................................................530 ACCUMULATORS....................................................................................................531 Low Precharge Warning Switch................................................................................531 HIGH PRESSURE FILTER............................................................................................531 STEERING/BRAKE PUMP.............................................................................................531 Operation.......................................................................................................532 PRINCIPLE OF OPERATION..........................................................................................534 Full Pump Volume:...........................................................................................534 Half Pump Volume:...........................................................................................534 STEERING CIRCUIT COMPONENT REPAIR...................................................................................537 BLEED DOWN MANIFOLD.............................................................................................537 Removal.....................................................................................................537 Installation................................................................................................537 ACCUMULATOR.....................................................................................................538 Removal.....................................................................................................538 Installation................................................................................................539 Disassembly.................................................................................................539 Cleaning and Inspection.....................................................................................539 Assembly....................................................................................................540 LEAK TESTING....................................................................................................541 STEERING ACCUMULATOR CHARGING PROCEDURE.........................................................................542 Temperature During Precharge................................................................................545 ACCUMULATOR STORAGE PROCEDURES..................................................................................546 INstructions For Storing Bladder Accumulators...............................................................546 Instructions For Installing A Bladder Accumulator That Was In A Parts Warehouse Or In Storage...............546 Bladder Storage Procedures..................................................................................547 FLOW AMPLIFIER..................................................................................................548 Removal.....................................................................................................548 Installation................................................................................................548 Disassembly.................................................................................................548 Reassembly..................................................................................................551 STEERING CONTROL UNIT...........................................................................................552 Removal.....................................................................................................552 Spline Inspection...........................................................................................552 Installation................................................................................................552 Disassembly.................................................................................................553 Cleaning and Inspection.....................................................................................554 Assembly....................................................................................................554 STEERING CYLINDER...............................................................................................558 Disassembly.................................................................................................558 Inspection and Cleaning.....................................................................................558 Assembly....................................................................................................558 STEERING CIRCUIT FILTER.........................................................................................559 FILTER ELEMENT REPLACEMENT..................................................................................559 Removal.....................................................................................................560 Installation................................................................................................560 INDICATOR SWITCH............................................................................................560 STEERING AND BRAKE PUMP.........................................................................................561 Removal.....................................................................................................561 Installation................................................................................................561 Disassembly.................................................................................................563 Control Piston Group........................................................................................563 Valve Plate Group...........................................................................................563 Rotating Group..............................................................................................564 Swashblock Group............................................................................................564 Driveshaft Group............................................................................................564 INSPECTION......................................................................................................564 Control Piston Group........................................................................................564 Valve Plate Group...........................................................................................564 Rotating Group..............................................................................................564 Swashblock Group............................................................................................568 Driveshaft Group............................................................................................568 Compensator Block and Unloader Module.......................................................................568 Stroke Adjuster Assembly....................................................................................568 ASSEMBLY........................................................................................................568 Swashblock Group............................................................................................568 Control Piston Group........................................................................................570 Valve Plate Group...........................................................................................570 HOIST CIRCUIT.......................................................................................................573 HOIST CIRCUIT OPERATION.........................................................................................573 COMPONENT DESCRIPTION...........................................................................................574 Hydraulic Tank..............................................................................................574 Hoist Pump..................................................................................................574 High Pressure Filters.......................................................................................574 Hoist Valve.................................................................................................575 Hoist Pilot Valve...........................................................................................576 Hoist-up Limit Solenoid.....................................................................................576 Pilot Operated Check Valve..................................................................................576 Counterbalance Valve Manifold...............................................................................576 HOIST SYSTEM OPERATION MODES....................................................................................577 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)................................................578 Power Up Operation (Figure 7-7).............................................................................580 Hold Operation (Figure 7-8).................................................................................582 Power Down Operation (Figure 7-9)...........................................................................584 Float Operation (Figure 7-10)...............................................................................586 HOIST CIRCUIT COMPONENT REPAIR......................................................................................589 HOIST VALVE.....................................................................................................589 Removal.....................................................................................................589 Installation................................................................................................589 O-Ring Replacement..........................................................................................590 INLET SECTION...............................................................................................590 Disassembly.................................................................................................590 Cleaning and Inspection.....................................................................................591 Assembly....................................................................................................592 SPOOL SECTION...............................................................................................592 Disassembly.................................................................................................592 Cleaning and Inspection.....................................................................................594 Assembly....................................................................................................594 HOIST PILOT VALVE...............................................................................................595 Removal.....................................................................................................595 Installation................................................................................................595 Disassembly.................................................................................................595 Cleaning and Inspection.....................................................................................597 Assembly....................................................................................................597 BODY UP LIMIT SOLENOID..........................................................................................598 PILOT OPERATED CHECK VALVE......................................................................................598 HOIST CYLINDERS.................................................................................................598 Removal.....................................................................................................598 Installation................................................................................................599 Disassembly.................................................................................................601 Cleaning and Inspection.....................................................................................602 ASSEMBLY OF QUILL AND CYLINDER..................................................................................603 Quill Installation..........................................................................................603 Installation of Check Balls and Plugs in Quill..............................................................604 Assembly of Cylinder........................................................................................605 COUNTERBALANCE MANIFOLD.........................................................................................606 DISABLED TRUCK DUMPING PROCEDURE................................................................................607 HOOKUP......................................................................................................607 DUMPING PROCEDURE...........................................................................................607 HYDRAULIC CHECKOUT PROCEDURE........................................................................................609 STEERING AND BRAKE PUMP.........................................................................................609 Pressure Check And Adjustment Procedure.........................................................................609 BLEEDDOWN MANIFOLD..........................................................................................610 SHOCK & SUCTION VALVES..........................................................................................611 Shock & Suction Valve Settings..............................................................................611 LEAKAGE TESTS...................................................................................................612 Steering Control Unit & Flow Amplifier......................................................................612 Bleeddown Manifold..........................................................................................612 ACCUMULATOR BLEED DOWN PROCEDURE................................................................................613 LOW STEERING PRESSURE SWITCH....................................................................................613 CHECKING HOIST SYSTEM PRESSURES.................................................................................620 Hoist System Relief Pressure Adjustment.....................................................................620 Power Down Relief Pressure Adjustment.......................................................................621 Hoist Counterbalance Valve Adjustment.......................................................................622 Preparation:............................................................................................622 Counterbalance Valve Pressure Check Only:...............................................................622 Counterbalance Valve Adjustment.........................................................................623 HYDRAULIC SYSTEM FLUSHING PROCEDURE.............................................................................626 OIL CLEANLINESS CHECK.......................................................................................627 OPTIONS AND SPECIAL TOOLS...............................................................................................629 FIRE CONTROL SYSTEM (MANUAL)........................................................................................631 Operation.......................................................................................................631 Inspection and Maintenance......................................................................................631 Recharging Procedures...........................................................................................632 WIGGINS QUICK FILL FUEL SYSTEM......................................................................................633 FUEL RECEIVER...................................................................................................633 TANK BREATHER VALVE.............................................................................................634 Removal.....................................................................................................634 Installation................................................................................................634 Disassembly.................................................................................................634 Assembly....................................................................................................634 LEFT SIDE FILL..................................................................................................635 BUCKEYE QUICK FUEL SYSTEM...........................................................................................637 FUEL TANK BREATHER VALVE........................................................................................637 Maintenance.................................................................................................637 Filter Service..............................................................................................637 Disassembly.................................................................................................637 Inspection..................................................................................................637 Assembly....................................................................................................637 FUEL RECEIVER...................................................................................................638 ENGINE COOLANT HEATER...............................................................................................639 Maintenance.....................................................................................................639 HEATING ELEMENT.................................................................................................639 Removal.........................................................................................................639 Installation....................................................................................................639 THERMOSTAT......................................................................................................640 Removal.........................................................................................................640 Installation....................................................................................................640 SPECIAL TOOLS.......................................................................................................641 AIR CONDITIONING SYSTEM.............................................................................................647 Environmental Impact............................................................................................647 OPERATOR CAB AIR CONDITIONING...................................................................................648 PRINCIPLES OF REFRIGERATION.....................................................................................648 Air Conditioning............................................................................................648 Refrigeration - The Act Of Cooling..........................................................................649 The Refrigeration Cycle.....................................................................................649 AIR CONDITIONER SYSTEM COMPONENTS...............................................................................650 Compressor (Refrigerant Pump)...............................................................................650 Service Valves..............................................................................................650 Condenser...................................................................................................650 Expansion Block Valve.......................................................................................651 Evaporator..................................................................................................651 ELECTRICAL CIRCUIT..............................................................................................652 Thermostat..................................................................................................652 Compressor Clutch...........................................................................................652 Trinary™ Switch.............................................................................................653 SYSTEM SERVICING................................................................................................654 SYSTEM OIL......................................................................................................655 Handling and Reusing PAG Oil................................................................................655 Oil Quantity................................................................................................655 Replacing Oil After Servicing the System....................................................................655 Setting Up a New Compressor.................................................................................655 REFRIGERANT.....................................................................................................656 Recycled Refrigerant........................................................................................656 Reclaimed Refrigerant.......................................................................................656 Refrigerant Quantity........................................................................................656 R-134a Refrigerant Containers...............................................................................656 SERVICE TOOLS AND EQUIPMENT.....................................................................................657 Recovery/Recycle Station....................................................................................657 Leak Detector...............................................................................................657 Service Valves..............................................................................................658 Vacuum Pump.................................................................................................658 Manifold Gauge Set..........................................................................................659 Installing Manifold Gauge Set...............................................................................660 Purging Air From Service Hoses..............................................................................661 Stabilizing the AC System...................................................................................662 SYSTEM PERFORMANCE TEST.........................................................................................662 SYSTEM LEAK TESTING.............................................................................................663 Electronic leak detector....................................................................................663 Tracer dyes.................................................................................................663 Soap and water..............................................................................................663 SYSTEM REPAIR...................................................................................................664 System Cleaning.............................................................................................664 Hoses and Fittings..........................................................................................664 Lines.......................................................................................................664 Expansion Valve.............................................................................................664 Receiver-Drier..............................................................................................665 Thermostat..................................................................................................665 Compressor..................................................................................................665 Clutch......................................................................................................665 Servicing the Compressor Clutch.............................................................................666 Pulley Removal..............................................................................................668 Clutch Coil Check...........................................................................................668 Pulley Installation.........................................................................................668 Clutch Assembly Installation................................................................................669 RECOVERING AND RECYCLING THE REFRIGERANT........................................................................670 Performing the Recovery Cycle...............................................................................670 Performing the Recycling Procedure..........................................................................670 Evacuating and Charging the AC System.......................................................................670 EVACUATING THE SYSTEM...........................................................................................671 CHARGING THE AC SYSTEM..........................................................................................672 TROUBLESHOOTING.................................................................................................673 Pre-Diagnosis Checks........................................................................................673 Preparing For Diagnosis.....................................................................................673 Preliminary Steps...........................................................................................673 System Performance Test.....................................................................................673 Diagnosis Of Gauge Readings And System Performance..........................................................674 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM.................................................................681 RADIATOR SHUTTERS...................................................................................................683 OPERATION.......................................................................................................683 Hydraulic Circuit...........................................................................................683 Electrical Circuit:.........................................................................................684 MAINTENANCE AND REPAIR..........................................................................................684 TROUBLESHOOTING.................................................................................................686 Hydraulic Troubleshooting...................................................................................689 Electrical Troubleshooting..................................................................................691 Electrical troubleshooting..................................................................................692 PAYLOAD METER III ™.................................................................................................695 OPERATION SECTION...............................................................................................699 Introduction................................................................................................699 Data Summary............................................................................................699 Data Gathering..........................................................................................699 COMPONENT DESCRIPTION.......................................................................................700 System Diagram..........................................................................................700 Suspension Pressure Sensors.............................................................................700 Inclinometer............................................................................................700 Operator Display........................................................................................700 Operator Switch.........................................................................................701 Speed Input.............................................................................................701 Body-Up Switch..........................................................................................701 Brake Lock Switch.......................................................................................701 Payload Meter...........................................................................................701 Communications Ports....................................................................................701 Key Switch Input........................................................................................702 Payload Meter Power.....................................................................................702 Load Lights.............................................................................................702 Wiring and Termination..................................................................................703 TCI Outputs.............................................................................................703 OPERATOR’S DISPLAY AND SWITCH...............................................................................704 Reading the Speedometer.................................................................................704 Reading the Load Display................................................................................704 Using the Operator ID...................................................................................704 Using the Load and Ton Counter..........................................................................704 Total Ton Counter.......................................................................................704 Total Load Counter......................................................................................705 Clearing the Counters...................................................................................705 Viewing Live Sensor Data................................................................................705 Other Display Messages..................................................................................705 PAYLOAD OPERATION & CALCULATION.............................................................................706 Description of Haul Cycle States........................................................................706 Haul Cycle Description..................................................................................706 Load Calculation........................................................................................707 Carry Back..............................................................................................707 Measurement Accuracy....................................................................................707 SOURCES FOR PAYLOAD ERROR...................................................................................707 Payload Error...........................................................................................707 Loading Conditions......................................................................................708 Pressure Sensors........................................................................................708 Swingloads..............................................................................................708 Speed and Distance......................................................................................708 HAUL CYCLE DATA.............................................................................................708 Haul Cycle Warning Flags................................................................................710 Frame Torque Data.......................................................................................711 Sprung Weight Data......................................................................................711 Maximum Speed Data......................................................................................711 Alarm Records...........................................................................................711 Fault Code Data.........................................................................................712 PC SOFTWARE OVERVIEW........................................................................................713 System Configuration....................................................................................713 Installing the PLMIII Software..........................................................................713 DOWNLOADING DATA............................................................................................714 PLM III SYSTEM CONFIGURATION................................................................................715 Starting Communications.................................................................................715 Displayed Payload Units.................................................................................715 Time Units..............................................................................................715 Connection Menu.........................................................................................715 Connecting to the Payload Meter.........................................................................716 Configure the Payload Meter.............................................................................716 Setting the Date and Time...............................................................................716 Setting the Truck Type..................................................................................717 Setting the Gauge Display Units.........................................................................717 Setting the Frame Serial Number.........................................................................717 Setting the Truck Number................................................................................717 Setting the Komatsu Distributor.........................................................................717 Setting the Komatsu Customer............................................................................717 Clean Truck Tare........................................................................................718 Inclinometer Calibration................................................................................718 DATA ANALYSIS...............................................................................................719 Creating a Query........................................................................................719 Sorting on Truck Unit Number............................................................................719 Sorting on Truck Type...................................................................................719 Sorting on Date Range...................................................................................720 Sorting on Time Range...................................................................................720 Payload Detail Screen...................................................................................721 Creating Reports........................................................................................721 Summary - one page report...............................................................................722 Detailed - multi-page report............................................................................722 Creating Graphs.........................................................................................723 Exporting Data..........................................................................................723 CSV Export..............................................................................................723 Compressed..............................................................................................724 Importing Data..........................................................................................725 Deleting Haul Cycle Records.............................................................................725 Viewing Alarms..........................................................................................726 Deleting Alarm Records..................................................................................726 TROUBLESHOOTING SECTION.....................................................................................727 TROUBLESHOOTING.........................................................................................727 Viewing Active Alarms...............................................................................727 Real-Time Data Display..............................................................................727 Testing the Payload Lights..........................................................................727 Creating Log Files of Inputs........................................................................728 Daily Inspections...................................................................................728 Periodic Maintenance................................................................................728 Abnormal Displays at Power-Up.......................................................................729 No Payload Display When Key Switch is Turned ON.....................................................730 No Display on Speedometer...........................................................................731 No Display on Operator Display......................................................................731 No Communications With PC...........................................................................732 Load Lights Don’t Light During Loading..............................................................733 Load Lights Remain ON...............................................................................734 Load Lights Remain ON During Dumping................................................................734 Display Doesn't Clear When The Load Is Dumped.......................................................734 Calibration Problems................................................................................735 Alarm 1 - Left Front Pressure High..................................................................736 Alarm 2 - Left Front Pressure Low...................................................................736 Troubleshoot Wiring to Left Front Suspension........................................................736 Alarm 3 - Right Front Pressure High.................................................................737 Alarm 4 - Right Front Pressure Low..................................................................737 Troubleshoot Wiring to Right Front Suspension.......................................................737 Alarm 5 -Left Rear Pressure High....................................................................738 Alarm 6 - Left Rear Pressure Low....................................................................738 Troubleshoot Wiring to Left Rear Suspension.........................................................738 Alarm 7 - Right Rear Pressure High..................................................................739 Alarm 8 - Right Rear Pressure Low...................................................................739 Troubleshoot Wiring to Right Rear Suspension........................................................739 Alarm 9 - Inclinometer High.........................................................................740 Alarm 10 - Inclinometer Low.........................................................................740 Troubleshoot Inclinometer Wiring....................................................................740 Alarm 13 - Body Up Input Failure....................................................................741 Alarm 16 - Memory Write Failure.....................................................................742 Alarm 17 - Memory Read Failure......................................................................742 Alarm 18............................................................................................743 Alarm 19............................................................................................743 Alarm 22............................................................................................743 Operator Switch Doesn't Work........................................................................744 Alarm 26 - User Switch Fault - SELECT...............................................................744 Alarm 27 - User Switch Fault - SET..................................................................744 Connector Map.......................................................................................745 Connectors..........................................................................................746 PLMIII CHECK OUT PROCEDURE..................................................................................747 General Description.....................................................................................747 Tools Required..........................................................................................747 Checkout Procedure......................................................................................747 PLMIII CHECKOUT PROCEDURE CONFIRMATION..................................................................751 Flashburn Programming...............................................................................751 Confirmation Checklist..............................................................................753 RESERVE ENGINE OIL SYSTEM...........................................................................................755 Extend oil change intervals.....................................................................................755 Operation.......................................................................................................756 LED Monitor Light...............................................................................................756 Tank Fill Control (Optional)....................................................................................757 Service.........................................................................................................758 Changing Oil....................................................................................................758 TROUBLESHOOTING.................................................................................................759 System Electrical Schematics................................................................................760 OPERATORS CAB...........................................................................................................761 TRUCK CAB...........................................................................................................763 Description.....................................................................................................763 Removal.....................................................................................................764 Installation................................................................................................765 CAB DOOR........................................................................................................766 Removal.....................................................................................................766 Installation................................................................................................766 Door Adjustment.............................................................................................766 Door Jamb Bolt Adjustment...................................................................................766 Door Handle Plunger Adjustment..............................................................................768 Replace Door Glass..........................................................................................769 Replace Door Window Regulator...............................................................................773 Replace Door Handle or Latch Assembly.......................................................................773 Door and Door Hinge Seal Replacement........................................................................774 Door Opening Seal Removal...................................................................................774 Installation................................................................................................774 GLASS REPLACEMENT...............................................................................................775 ADHESIVE-BONDED WINDOWS.....................................................................................775 Replacement Procedure.......................................................................................775 WINDSHIELD & REAR GLASS.....................................................................................776 Removal.....................................................................................................776 Installation................................................................................................777 CAB COMPONENTS......................................................................................................779 WINDSHIELD WIPERS...............................................................................................779 Wiper Motor.....................................................................................................779 Removal.....................................................................................................779 Installation................................................................................................779 Wiper Arm.......................................................................................................779 Removal.....................................................................................................779 Installation................................................................................................780 Wiper Linkage...................................................................................................780 Removal.....................................................................................................780 Installation................................................................................................780 WINDSHIELD WASHER...............................................................................................781 Operation...................................................................................................781 Service.....................................................................................................781 OPERATOR COMFORT....................................................................................................783 HEATER/AIR CONDITIONER CONTROLS.................................................................................784 OPERATION...................................................................................................784 HEATER/AIR CONDITIONER..........................................................................................785 OPERATION...................................................................................................785 HEATER COMPONENTS...............................................................................................785 CIRCUIT BREAKERS............................................................................................785 RELAYS......................................................................................................785 HEATER CORE.................................................................................................786 FAN MOTOR AND SPEED CONTROL.................................................................................786 Test........................................................................................................786 ACTUATORS...................................................................................................786 Test........................................................................................................786 FILTER......................................................................................................786 Service.....................................................................................................786 AIR CONDITIONER COMPONENTS......................................................................................786 OPERATOR CONTROLS AND EQUIPMENT.....................................................................................789 STEERING WHEEL AND CONTROLS.....................................................................................790 Horn Button.................................................................................................790 Tilt / Telescope Lever......................................................................................790 Multi-Function Turn Signal Switch...........................................................................790 STEERING COLUMN.................................................................................................791 Removal.....................................................................................................791 Steering Column Inspection..................................................................................791 Installation................................................................................................791 PEDAL CONTROLS..................................................................................................792 Throttle Pedal..............................................................................................792 Service Brake Pedal.........................................................................................792 Optional Dual Function/ Single Pedal........................................................................792 Dynamic Retarding Pedal.....................................................................................792 OVERHEAD PANEL AND DISPLAY......................................................................................793 Grade/speed Warning Chart...................................................................................793 Radio Speakers..............................................................................................793 Warning Alarm Buzzer........................................................................................793 Cab Radio...................................................................................................793 Warning Lights Dimmer Control...............................................................................793 Status / Warning Indicator Light Panel......................................................................793 Windshield Wipers...........................................................................................793 Air Cleaner Vacuum Gauges...................................................................................794 CENTER CONSOLE CONTROLS.........................................................................................794 F-N-R Selector Switch.......................................................................................794 Hoist Control...............................................................................................795 Ash Tray....................................................................................................795 Lighter.....................................................................................................795 Window Switches.............................................................................................795 Engine Shutdown Switch......................................................................................795 Override Switch.............................................................................................796 Retard Speed Control (RSC) Switch...........................................................................796 Retard Speed Control (RSC) Adjust Dial......................................................................796 Operation...................................................................................................796 RSC Control Adjustment......................................................................................797 Statex III Propulsion System Diagnostic Connector...........................................................797 Modular Mining Port Conector................................................................................797 Komatsu Engine Quantum Connector............................................................................797 Komatsu Engine Cense Connector..............................................................................797 Data Store Button...........................................................................................797 Passenger Seat..............................................................................................797 Service Engine Light (Blue).................................................................................797 Payload Meter (Not Shown)...................................................................................797 INSTRUMENT PANEL & INDICATOR LIGHTS.............................................................................798 CONTROL SYMBOLS.............................................................................................798 INSTRUMENT PANEL GAUGES, INDICATORS, & CONTROLS.................................................................799 Key Switch..................................................................................................800 Engine Shutdown Switch (with Timer Delay)...................................................................800 Operation...................................................................................................800 To Cancel Delay Sequence....................................................................................800 Fog Lights (Optional).......................................................................................800 Ladder Light Switch.........................................................................................800 Backup Light Switch.........................................................................................800 Panel Illumination Lights...................................................................................801 Cab Air Conditioner/heater Vents............................................................................801 Engine Cold Weather Starting Aid (Optional).................................................................801 Operation...................................................................................................801 Rotating Beacon Light Switch (Optional).....................................................................801 Heated Mirror Switch (Optional).............................................................................801 Blank (Not Used In This Application)........................................................................801 Wheel Brake Lock Control....................................................................................801 Operation...................................................................................................801 Parking Brake Control.......................................................................................802 Tachometer..................................................................................................802 Right Turn Signal Indicator.................................................................................802 High Beam Indicator.........................................................................................802 Left Turn Signal Indicator..................................................................................802 Speedometer / Payload Meter.................................................................................802 Voltmeter...................................................................................................802 Engine Oil Pressure Gauge...................................................................................802 Water Temperature Gauge.....................................................................................803 Fuel Gauge..................................................................................................803 Blank.......................................................................................................803 Hourmeter...................................................................................................803 The hourmeter (24, Figure 5- 7) registers the total number of hours the truck engine has been operating.....803 Blank.......................................................................................................803 Headlight Switch............................................................................................803 Panel Light Dimmer..........................................................................................803 Payload Meter Switch........................................................................................803 OVERHEAD STATUS / WARNING INDICATOR LIGHTS......................................................................804 INDICATOR LIGHTS............................................................................................805 VEHICLE HEALTH MONITORING SYSTEM (VHMS).........................................................................810 Operation...................................................................................................810 Interface Module............................................................................................811 Basic Precautions...........................................................................................811 LUBRICATION AND SERVICE.................................................................................................813 LUBRICATION AND SERVICE.............................................................................................815 Service Capacities..............................................................................................815 HYDRAULIC TANK SERVICE..........................................................................................815 Adding Oil..................................................................................................815 COOLANT LEVEL CHECK.............................................................................................816 Radiator Filling Procedure..................................................................................816 Anti-Freeze Specifications..................................................................................816 RESERVE ENGINE OIL SYSTEM (Optional)............................................................................816 Reserve Oil Tank Filling Procedure (Remote fill)............................................................816 10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS..............................................................818 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................................................821 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................................................822 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................................................823 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................................................826 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS...................................................................828 2500 HOUR MAINTENANCE CHECKS....................................................................................829 5000 HOUR MAINTENANCE CHECKS....................................................................................829 10,000 HOUR MAINTENANCE CHECKS..................................................................................830 AUTOMATIC LUBRICATION SYSTEM........................................................................................831 GENERAL DESCRIPTION.............................................................................................831 SYSTEM COMPONENTS...............................................................................................833 System Operation................................................................................................834 Normal Operation............................................................................................834 Pressure Failure Detection Circuits.........................................................................835 INJECTOR OPERATION..............................................................................................836 GENERAL INSTRUCTIONS............................................................................................837 LUBRICANT REQUIRED FOR SYSTEM...............................................................................837 SYSTEM PRIMING..............................................................................................837 FILTER ASSEMBLY.............................................................................................837 LUBRICANT PUMP..............................................................................................838 Pump Housing Oil Level......................................................................................838 Pump Pressure Control.......................................................................................838 Pressure Control Valve Adjustment...........................................................................838 INJECTORS (SL-1 Series "H").................................................................................839 Injector Specifications.....................................................................................839 Injector Adjustment.........................................................................................839 SYSTEM CHECKOUT.............................................................................................840 24 VDC TIMER CHECK......................................................................................840 Lubrication Cycle Timer Adjustment......................................................................840 PUMP REBUILD............................................................................................841 Disassembly.............................................................................................841 Cleaning and Inspection.................................................................................841 Assembly................................................................................................843 SYSTEM TROUBLESHOOTING CHART....................................................................................844 Preventative Maintenance Procedures.........................................................................847 Daily Lubrication System Inspection.....................................................................847 250 Hour Inspection.....................................................................................847 1000 Hour Inspection....................................................................................847 MOTORIZED WHEEL MAINTENANCE SCHEDULE................................................................................849 AXLE BOX........................................................................................................849 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................................850 ARMATURE AREA...............................................................................................850 AT TIRE CHANGE - FOR ALL MOTORIZED WHEELS...................................................................850 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................................851 GENERATOR / ALTERNATOR......................................................................................851 GRID BLOWER MOTOR...........................................................................................851 CONTROL EQUIPMENT CHECKS....................................................................................851 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................................852 AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM..............................................................852 VEHICLE OPERATIONS TESTS....................................................................................852 SECTION Q INDEX.............................................................................................853 SYSTEM SCHEMATICS...........................................................................................857 ALPHABETICAL INDEX......................................................................................................853 SYSTEM SCHEMATICS.......................................................................................................857 HH353 HYDRAULIC SCHEMATIC...........................................................................................859 HH354 BRAKE SCHEMATIC...............................................................................................860 EL0114 VHMS ELECTRICAL SCHEMATIC....................................................................................861 XS1400 ELECTRIC SCHEMATIC...........................................................................................866
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