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KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30990-A31054 TIER-2) – PDF Download
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- KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER: A30990-A31054 TIER-2
- PUBLICATION NUMBER:CEBM023902
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KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30990-A31054 TIER-2)
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30990-A31054 TIER-2) – PDF DOWNLOAD:
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KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30990-A31054 TIER-2)
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
- All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing 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 typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise.
- When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts in the General Information section of this manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.
- A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model.
- The letter “E” designates an Electrical wheel motor drive system. The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, see the end of Section A4. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
TABLE OF CONTENTS:
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30990-A31054 TIER-2)
COVER................................................................................................................................. 1 FOREWORD.............................................................................................................................. 5 TABLE OF CONTENTS..................................................................................................................... 7 SECTION A GENERAL INFORMATION......................................................................................................... 9 COMPONENTS & SPECIFICATIONS....................................................................................................... 11 MAJOR COMPONENT DESCRIPTIONS.................................................................................................. 11 Truck And Engine.......................................................................................................... 11 Main Alternator........................................................................................................... 11 AC Induction Traction Motorized Wheels.................................................................................... 11 Suspension................................................................................................................ 11 Operator's Cab............................................................................................................ 11 Power Steering............................................................................................................ 11 Dynamic Retarding......................................................................................................... 11 Brake System.............................................................................................................. 11 SPECIFICATIONS................................................................................................................ 13 ENGINE.................................................................................................................... 13 AC ELECTRIC DRIVE SYSTEM.................................................................................................. 13 DYNAMIC RETARDING......................................................................................................... 13 BATTERY ELECTRIC SYSTEM................................................................................................... 13 SERVICE CAPACITIES........................................................................................................ 13 HYDRAULIC SYSTEMS......................................................................................................... 14 SERVICE BRAKES............................................................................................................ 14 STEERING.................................................................................................................. 14 TIRES..................................................................................................................... 14 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS.............................................................................. 14 WEIGHT DISTRIBUTION....................................................................................................... 15 SAFETY............................................................................................................................ 17 GENERAL....................................................................................................................... 17 Safety Rules.............................................................................................................. 17 Safety Features........................................................................................................... 17 Fire Extinguisher And First Aid Kit....................................................................................... 17 Clothing And Personal Items............................................................................................... 17 Leaving The Operator’s Seat............................................................................................... 18 Mounting And Dismounting.................................................................................................. 18 Fire Prevention For Fuel And Oil.......................................................................................... 18 Precautions With High Temperature Fluids.................................................................................. 19 Asbestos Dust Hazard Prevention........................................................................................... 19 Prevention Of Injury By Work Equipment.................................................................................... 19 Unauthorized Modification................................................................................................. 19 Precautions When Using ROPS............................................................................................... 19 Precautions For Attachments............................................................................................... 20 Precautions For Starting The Truck........................................................................................ 20 PRECAUTIONS BEFORE OPERATION.................................................................................................. 20 Safety At The Worksite.................................................................................................... 20 Fire Prevention........................................................................................................... 21 Ventilation In Enclosed Areas............................................................................................. 21 Preparing For Operation................................................................................................... 21 Mirrors, Windows And Lights............................................................................................... 21 In The Operator Cab (Before Starting The Engine).......................................................................... 21 Seat Belts................................................................................................................ 21 OPERATING THE TRUCK........................................................................................................... 22 When Starting The Engine.................................................................................................. 22 General Truck Operation................................................................................................... 22 Ensuring Good Visibility.................................................................................................. 22 Traveling................................................................................................................. 23 Traveling In Reverse...................................................................................................... 23 Traveling On Slopes....................................................................................................... 23 Operating On Snow Or Ice.................................................................................................. 23 Avoid Damage To Dump Body................................................................................................. 23 Driving Near High Voltage Cables.......................................................................................... 24 Working On Loose Ground................................................................................................... 24 When Dumping.............................................................................................................. 24 When Loading.............................................................................................................. 24 Parking The Truck......................................................................................................... 24 Towing.................................................................................................................... 24 WORKING NEAR BATTERIES........................................................................................................ 25 Battery Hazard Prevention................................................................................................. 25 Jump Starting With Booster Cables......................................................................................... 26 Jump Starting With Receptacles............................................................................................ 26 BEFORE PERFORMING MAINTENANCE................................................................................................. 27 Stopping The Engine Before Service........................................................................................ 27 Warning Tag............................................................................................................... 27 Proper Tools.............................................................................................................. 27 Use of Tie-Off Anchor During Maintenance and Repair....................................................................... 27 Securing The Dump Body.................................................................................................... 28 WHILE PERFORMING MAINTENANCE.................................................................................................. 29 Keep The Truck Clean...................................................................................................... 29 Attachments............................................................................................................... 29 Working Under The Truck................................................................................................... 29 Rotating Fan And Belts.................................................................................................... 29 Waste Materials........................................................................................................... 29 Adding Fuel Or Oil........................................................................................................ 30 Radiator Coolant Level.................................................................................................... 30 Use Of Lighting........................................................................................................... 30 Precautions With The Battery.............................................................................................. 30 Handling High Pressure Hoses.............................................................................................. 30 Precautions With High Pressure Oil........................................................................................ 30 Performing Maintenance Near High Temperature Or High Pressure............................................................. 30 TIRES......................................................................................................................... 31 Handling Tires............................................................................................................ 31 Tire Maintenance.......................................................................................................... 31 Storing Tires After Removal............................................................................................... 31 WHEN REPAIRS ARE NECESSARY.................................................................................................... 32 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS............................................................................ 33 Preliminary Procedures Before Welding or Performing Maintenance........................................................... 33 Engine Shutdown Procedure Before Welding or Performing Maintenance........................................................ 33 CAPACITOR DISCHARGE SYSTEM.................................................................................................... 35 Necessary Tools........................................................................................................... 35 Warnings And Cautions..................................................................................................... 36 Manual DC Link Capacitor Discharge Procedure.............................................................................. 37 Failure of the Discharge System........................................................................................... 39 Manual Discharge of Capacitors............................................................................................ 40 Short Isolated Capacitor Terminals........................................................................................ 42 OPERATING INSTRUCTIONS............................................................................................................ 43 PREPARING FOR OPERATION....................................................................................................... 43 WALK AROUND INSPECTION........................................................................................................ 43 RETRACTABLE LADDER SYSTEM (Optional).......................................................................................... 47 Description............................................................................................................... 47 Normal Operation.......................................................................................................... 47 General Safety............................................................................................................ 47 IN-CAB CONTROL PANEL.......................................................................................................... 48 Digital Display Screen.................................................................................................... 48 Command Buttons........................................................................................................... 48 USING THE IN-CAB CONTROL PANEL................................................................................................ 49 Raising the Ladder........................................................................................................ 50 Lowering the Ladder....................................................................................................... 50 USING THE GROUND LEVEL CONTROL BOX............................................................................................ 51 Raising the Ladder........................................................................................................ 51 Lowering the Ladder....................................................................................................... 51 EMERGENCY OPERATION........................................................................................................... 51 ENGINE START-UP............................................................................................................... 52 AFTER ENGINE HAS STARTED...................................................................................................... 53 PRE-SHIFT BRAKE CHECK......................................................................................................... 53 Events.................................................................................................................... 53 OPERATION..................................................................................................................... 54 Description............................................................................................................... 54 Brake Test Exit Criteria.................................................................................................. 54 PERFORMING THE BRAKE TESTS.................................................................................................... 55 Setup..................................................................................................................... 55 Service Brake Test........................................................................................................ 55 Parking Brake Test........................................................................................................ 56 Retard System Test........................................................................................................ 57 EMERGENCY STEERING SYSTEM..................................................................................................... 57 Operation................................................................................................................. 57 Pre-Operation Testing..................................................................................................... 57 MACHINE OPERATION SAFETY PRECAUTIONS.......................................................................................... 58 OPERATING ON THE HAUL ROAD.................................................................................................... 59 STARTING ON A GRADE WITH A LOADED TRUCK....................................................................................... 60 PASSING....................................................................................................................... 60 LOADING....................................................................................................................... 60 Overload Speed Limit Function............................................................................................. 60 DUMPING....................................................................................................................... 61 Raising The Dump Body..................................................................................................... 61 Lowering The Dump Body (When dumping on flat ground)...................................................................... 62 Lowering The Dump Body (When dumping over a berm or into a crusher)....................................................... 62 TOWING........................................................................................................................ 63 Special Wiring Harness.................................................................................................... 63 SAFE PARKING PROCEDURES....................................................................................................... 65 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................................................................. 65 SUDDEN LOSS OF ENGINE POWER................................................................................................... 66 FUEL DEPLETION................................................................................................................ 66 DISABLED TRUCK DUMPING PROCEDURE.............................................................................................. 67 Hookup.................................................................................................................... 67 Raising the Body.......................................................................................................... 67 Lowering the Body......................................................................................................... 67 WARNINGS AND CAUTIONS............................................................................................................. 69 GRADE/SPEED CHART............................................................................................................. 69 KEY SWITCH.................................................................................................................... 69 ROPS/FOPS..................................................................................................................... 69 BATTERIES..................................................................................................................... 70 CAPACITORS.................................................................................................................... 70 CRUSHING HAZARD............................................................................................................... 71 CYLINDER PRESSURE............................................................................................................. 71 FILLING THE HYDRAULIC TANK.................................................................................................... 72 HYDRAULIC OIL PRESSURE........................................................................................................ 72 HOT OIL SPRAY................................................................................................................. 73 WHEEL MOTOR OIL LEVEL......................................................................................................... 73 HOT EXHAUST................................................................................................................... 73 RADIATOR...................................................................................................................... 73 EMERGENCY LADDER.............................................................................................................. 73 ACCUMULATOR DRAIN VALVES...................................................................................................... 73 EMERGENCY DUMP PROCEDURE...................................................................................................... 74 EMERGENCY TOWING PROCEDURE.................................................................................................... 74 WELDING....................................................................................................................... 74 EMERGENCY SHUTDOWN............................................................................................................ 74 INFORMATION DISPLAY........................................................................................................... 75 WIRELESS SIGNALS.............................................................................................................. 75 HIGH VOLTAGE.................................................................................................................. 75 LIFTING INSTRUCTIONS.......................................................................................................... 76 PRODUCT IDENTIFICATION PLATE.................................................................................................. 77 LUBRICATION CHART............................................................................................................. 78 TORQUE TABLES AND CONVERSION CHARTS............................................................................................... 79 STORAGE AND IDLE MACHINE PREPARATION.............................................................................................. 89 SHORT TERM IDLE PERIODS....................................................................................................... 89 PREPARATION FOR STORAGE....................................................................................................... 90 REMOVAL FROM STORAGE.......................................................................................................... 91 RECONDITIONING AN IDLE VEHICLE................................................................................................ 93 ENGINE OPERATION.............................................................................................................. 95 After The Engine Has Started.............................................................................................. 96 ENGINE STORAGE................................................................................................................ 97 Temporary Storage (30 Days Or Less)....................................................................................... 97 Extended Storage (More Than 30 Days)...................................................................................... 97 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................................................................... 99 ELECTRIC DRIVE TRUCKS......................................................................................................... 100 Storing A Truck That Is Operational....................................................................................... 100 Storing A Truck That Is Not Operational................................................................................... 101 Storing A Major Component................................................................................................. 102 Periodic Inspections...................................................................................................... 102 Placing Equipment Into Service After Storage.............................................................................. 102 SECTION B STRUCTURES.................................................................................................................. 105 SECTION B2 STRUCTURAL COMPONENTS.................................................................................................. 107 STRUCTURAL COMPONENTS......................................................................................................... 109 PREPARATION............................................................................................................... 109 DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY................................................................................. 110 Removal............................................................................................................... 110 Installation.......................................................................................................... 110 RH DECK AND RETARDING GRID................................................................................................ 111 Removal............................................................................................................... 111 Installation.......................................................................................................... 111 LH DECK................................................................................................................... 112 Removal............................................................................................................... 112 Installation.......................................................................................................... 112 CENTER DECK............................................................................................................... 113 Removal............................................................................................................... 113 Installation.......................................................................................................... 113 SECTION B3 DUMP BODY.............................................................................................................. 115 DUMP BODY..................................................................................................................... 117 DUMP BODY................................................................................................................. 117 Removal............................................................................................................... 117 Installation.......................................................................................................... 118 BODY PADS................................................................................................................. 119 Body Pad Shimming Procedure........................................................................................... 120 BODY GUIDE................................................................................................................ 121 HOIST LIMIT SWITCH........................................................................................................ 121 BODY-UP SWITCH............................................................................................................ 121 BODY RETENTION SLING...................................................................................................... 121 ROCK EJECTORS............................................................................................................. 122 Inspection............................................................................................................ 122 SECTION B4 FUEL TANK.............................................................................................................. 123 FUEL TANK..................................................................................................................... 125 FUEL TANK................................................................................................................. 125 Removal............................................................................................................... 125 Repair................................................................................................................ 125 Cleaning.............................................................................................................. 125 Installation.......................................................................................................... 125 FUEL TANK VENT ASSEMBLY................................................................................................... 127 Disassembly........................................................................................................... 127 Assembly.............................................................................................................. 127 FUEL GAUGE SENDER......................................................................................................... 128 Removal............................................................................................................... 128 Installation.......................................................................................................... 128 QUICK FILL FUEL RECEIVERS................................................................................................. 128 SECTION C ENGINE...................................................................................................................... 129 SECTION C2 POWER MODULE........................................................................................................... 131 POWER MODULE.................................................................................................................. 133 PREPARATION FOR REMOVAL................................................................................................... 133 REMOVAL................................................................................................................... 138 INSTALLATION.............................................................................................................. 140 HOOKUP.................................................................................................................... 141 SECTION C3 COOLING SYSTEM......................................................................................................... 143 COOLING SYSTEM................................................................................................................ 145 RADIATOR.................................................................................................................. 145 Removal............................................................................................................... 145 Installation.......................................................................................................... 147 Filling Procedure..................................................................................................... 148 REPAIRING THE RADIATOR.................................................................................................... 148 Internal Inspection................................................................................................... 148 External Cleaning..................................................................................................... 148 Disassembly........................................................................................................... 149 Cleaning and Inspection............................................................................................... 150 Assembly.............................................................................................................. 150 Pressure Testing...................................................................................................... 151 COOLANT SYSTEM TROUBLESHOOTING............................................................................................ 151 SECTION C4 POWER TRAIN............................................................................................................ 153 POWER TRAIN................................................................................................................... 155 ALTERNATOR REMOVAL........................................................................................................ 155 ALTERNATOR INSTALLATION................................................................................................... 157 Measuring Procedure................................................................................................... 157 Joining the Alternator and Engine..................................................................................... 159 ENGINE.................................................................................................................... 160 Removal............................................................................................................... 160 Service............................................................................................................... 160 Installation.......................................................................................................... 160 SECTION C5 AIR CLEANERS........................................................................................................... 161 AIR CLEANERS.................................................................................................................. 163 OPERATION................................................................................................................. 163 SERVICING THE AIR CLEANERS................................................................................................ 163 Replacing The Elements................................................................................................ 164 AIR CLEANER ASSEMBLY CLEANING............................................................................................. 165 Primary Element Cleaning.............................................................................................. 165 Precleaner Section Cleaning........................................................................................... 167 AIR INTAKE TROUBLESHOOTING................................................................................................ 168 SECTION C7 FAN CLUTCH............................................................................................................. 169 FAN CLUTCH.................................................................................................................... 171 REMOVAL & INSTALLATION TOOLING............................................................................................ 171 DISASSEMBLY............................................................................................................... 174 CLEANING AND INSPECTION................................................................................................... 184 ASSEMBLY.................................................................................................................. 188 TEST PROCEDURE............................................................................................................ 202 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION).................................................................................... 203 SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM......................................................................................... 205 24VDC ELECTRIC SUPPLY SYSTEM.................................................................................................. 207 ELECTRICAL SYSTEM DESCRIPTION............................................................................................. 207 BATTERIES................................................................................................................. 207 Maintenance and Service............................................................................................... 207 Troubleshooting....................................................................................................... 207 BATTERY SUPPLY SYSTEM..................................................................................................... 209 24VDC Battery Charging Alternator..................................................................................... 209 Batteries............................................................................................................. 209 Engine Start Relays................................................................................................... 209 24VDC Auxiliary Battery Receptacles................................................................................... 209 Battery Disconnect Switches........................................................................................... 209 24VDC to 12VDC Converter.............................................................................................. 210 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)....................................................................... 210 Operation............................................................................................................. 210 Pressure Switch....................................................................................................... 210 Check Valve........................................................................................................... 211 Timer Solenoid........................................................................................................ 211 MAINTENANCE............................................................................................................... 211 Prelube System Operation Checks....................................................................................... 211 Check Valve........................................................................................................... 211 Timer Solenoid........................................................................................................ 211 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT................................................................................ 212 24VDC ELECTRIC START SYSTEM................................................................................................... 214 CRANKING MOTORS........................................................................................................... 214 Operation............................................................................................................. 214 Removal............................................................................................................... 214 Installation.......................................................................................................... 214 CRANKING MOTOR TROUBLESHOOTING............................................................................................ 215 Preliminary Inspection................................................................................................ 215 No-Load Test.......................................................................................................... 215 Interpreting Results of Tests......................................................................................... 216 Disassembly........................................................................................................... 216 Cleaning and Inspection............................................................................................... 217 Armature Servicing.................................................................................................... 219 Field Coil Checks..................................................................................................... 219 Field Coil Removal.................................................................................................... 219 SOLENOID CHECKS........................................................................................................... 220 Test.................................................................................................................. 220 Assembly.............................................................................................................. 221 Bearing Replacement:.................................................................................................. 221 Motor Assembly:....................................................................................................... 221 Pinion Clearance...................................................................................................... 222 MAGNETIC SWITCH........................................................................................................... 222 Removal............................................................................................................... 222 Installation.......................................................................................................... 222 Coil Test............................................................................................................. 223 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS..................................................................................... 225 24 VDC ELECTRICAL SYSTEM COMPONENTS........................................................................................... 227 BRAKE WARNING BUZZER...................................................................................................... 227 AUXILIARY CONTROL CABINET COMPONENTS...................................................................................... 227 Power Distribution Terminals.......................................................................................... 227 Control Power Relay................................................................................................... 227 Auto Lube Timer....................................................................................................... 227 Ground Level Power Relay.............................................................................................. 227 Diode Board - DB1..................................................................................................... 229 Fuse Blocks........................................................................................................... 230 Alarm Indicating Device (AID) System.................................................................................. 230 RELAY BOARDS.............................................................................................................. 233 Relay Boards RB1, RB3, RB4, RB5....................................................................................... 233 Relay Board RB6, RB7, RB8, RB9........................................................................................ 235 Relay Board Functions................................................................................................. 236 BODY-UP SWITCH............................................................................................................ 238 Operation............................................................................................................. 238 Adjustment............................................................................................................ 238 Service............................................................................................................... 238 HOIST LIMIT SWITCH........................................................................................................ 239 Operation............................................................................................................. 239 Adjustment............................................................................................................ 239 Service............................................................................................................... 239 FUSE BLOCKS AND CIRCUIT BREAKERS.......................................................................................... 240 SECTION D11 KOMTRAX PLUS.......................................................................................................... 243 KOMTRAX PLUS.................................................................................................................. 245 KOMTRAX PLUS BASIC FEATURES............................................................................................... 245 Gather Data........................................................................................................... 245 Convert and Record Data............................................................................................... 245 Communicate Data to Off-Board Systems................................................................................. 246 USING KOMTRAX PLUS........................................................................................................ 247 Turning KOMTRAX Plus ON............................................................................................... 247 Normal KOMTRAX Plus Operation......................................................................................... 247 Turning KOMTRAX Plus OFF.............................................................................................. 248 Downloading from the KOMTRAX Plus Controller.......................................................................... 248 KOMTRAX PLUS DATA ITEMS................................................................................................... 249 Fault Codes........................................................................................................... 249 Machine History....................................................................................................... 249 KOMTRAX Plus History.................................................................................................. 249 Snapshots............................................................................................................. 250 Manual Snapshots...................................................................................................... 250 Trends................................................................................................................ 252 Histogram (Load Map) Data............................................................................................. 252 Haul Cycle Data....................................................................................................... 253 Alarm and Snapshot Triggers........................................................................................... 254 Satellite Features.................................................................................................... 254 KOMTRAX PLUS DIAGNOSTIC FEATURES.......................................................................................... 256 Fault History......................................................................................................... 256 LED Digits............................................................................................................ 256 KOMTRAX PLUS CONTROLLER................................................................................................... 256 Removal............................................................................................................... 257 Installation.......................................................................................................... 257 KOMTRAX PLUS SOFTWARE..................................................................................................... 258 VHMS Tool Box Installation............................................................................................ 258 VHMS Setting Tool Installation........................................................................................ 258 PDM Software Installation............................................................................................. 258 KOMTRAX PLUS INITIALIZATION PROCEDURE..................................................................................... 259 CONTROLLER SETUP PROCEDURE............................................................................................ 259 SNAPSHOT PROCEDURE.................................................................................................... 262 DOWNLOAD PROCEDURE.................................................................................................... 263 FTP UPLOAD PROCEDURE.................................................................................................. 264 INITIALIZATION FORMS.................................................................................................. 265 WHEN REPLACING A KOMTRAX PLUS CONTROLLER.................................................................................. 266 KOMTRAX PLUS CONTROLLER CHECKOUT.......................................................................................... 271 Necessary Equipment................................................................................................... 271 Preliminary........................................................................................................... 271 KOMTRAX Plus Controller Checkout Procedure............................................................................ 272 ORBCOMM CONTROLLER (if equipped).......................................................................................... 274 Removal............................................................................................................... 274 Installation.......................................................................................................... 274 SECTION D12 INTERFACE MODULE...................................................................................................... 275 INTERFACE MODULE.............................................................................................................. 277 Removal................................................................................................................... 277 Installation.............................................................................................................. 277 SENSORS....................................................................................................................... 278 Temperature Sensors....................................................................................................... 278 Pressure Sensors.......................................................................................................... 278 INTERFACE MODULE SOFTWARE..................................................................................................... 279 Flashburn Program Installation............................................................................................ 279 Interface Module Application Code Installation............................................................................ 280 Interface Module Realtime Data Monitor Software........................................................................... 280 INTERFACE MODULE CHECKOUT..................................................................................................... 281 Necessary Equipment....................................................................................................... 281 Preliminary............................................................................................................... 282 Check Digital Inputs To The Interface Module.............................................................................. 283 Check Analog Inputs To The Interface Module............................................................................... 286 Check Serial Interfaces To The Interface Module........................................................................... 286 Check Outputs From The Interface Module................................................................................... 287 SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING..................................................................... 289 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING............................................................................. 291 GENERAL................................................................................................................... 291 TROUBLESHOOTING........................................................................................................... 292 Communications Networks............................................................................................... 292 Coaxial Cable......................................................................................................... 292 FAULT CODES............................................................................................................... 292 Fault History......................................................................................................... 292 KOMTRAX Plus LED Display Fault Codes.................................................................................. 293 Chassis Fault Codes................................................................................................... 294 Engine Fault Codes.................................................................................................... 298 FAULT TREE ANALYSIS....................................................................................................... 304 Unable to connect to KOMTRAX Plus from laptop PC...................................................................... 304 Flashing Error Code N4-23 (PLM III Communications Fault).............................................................. 305 Flashing Error Code N4-22 (Engine Communications Fault)............................................................... 306 No Data Received By WebCARE........................................................................................... 307 Coaxial Cable Troubleshooting......................................................................................... 308 SECTION D14 KOMTRAX PLUS FORMS.................................................................................................... 309 KOMTRAX PLUS FORMS............................................................................................................ 311 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 311 KOMTRAX PLUS DATA DOWNLOAD................................................................................................ 312 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 313 KOMTRAX PLUS INITIALIZATION FORM.......................................................................................... 315 SECTION E ELECTRIC PROPULSION SYSTEM.................................................................................................. 317 SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS.................................................................................. 319 ELECTRICAL PROPULSION SYSTEM COMPONENTS....................................................................................... 321 GENERAL SYSTEM DESCRIPTION................................................................................................ 321 SYSTEM COMPONENTS......................................................................................................... 323 Propulsion System Controller (PSC).................................................................................... 323 Truck Control Interface (TCI)......................................................................................... 324 Diagnostic Information Display (DID) Panel............................................................................ 325 DID Panel Event Codes................................................................................................. 325 PSC SOFTWARE FUNCTIONS.................................................................................................... 344 Input Processing...................................................................................................... 344 State Machine......................................................................................................... 344 DC Link State......................................................................................................... 347 Engine Control........................................................................................................ 348 ALTERNATOR FIELD CONTROL.................................................................................................. 348 Desired Three-Phase Voltage........................................................................................... 348 Desired DC Link Voltage............................................................................................... 348 Self-Load............................................................................................................. 349 Propel Torque Control................................................................................................. 349 Retard Torque Control................................................................................................. 349 Wheel Slide Control................................................................................................... 350 Resistor Grid Control................................................................................................. 350 Chopper Voltage Control............................................................................................... 350 EVENT DETECTION AND PROCESSING............................................................................................ 350 Power-On Tests........................................................................................................ 350 Initiated Tests....................................................................................................... 351 Periodic Tests........................................................................................................ 351 EVENT RESTRICTIONS........................................................................................................ 351 EVENT LOGGING AND STORAGE................................................................................................. 351 Event History Buffer.................................................................................................. 352 Data Packs............................................................................................................ 352 To Record and Save a Data Pack to a Disk.............................................................................. 352 Event Reset........................................................................................................... 353 SERIAL DATA COMMUNICATIONS................................................................................................ 353 PSC - TCI Communications Processing................................................................................... 353 PSC - PTU Communications Processing................................................................................... 353 Inverter Communications Processing.................................................................................... 354 OUTPUT PROCESSING......................................................................................................... 354 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS.................................................................................. 354 Fast Start............................................................................................................ 354 Engine Shutdown/Engine Not Running.................................................................................... 354 Limp Home Mode........................................................................................................ 355 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS..................................................................... 356 ELECTRONIC ACCELERATOR AND RETARD PEDALS.................................................................................. 364 Removal............................................................................................................... 364 Installation.......................................................................................................... 364 Disassembly........................................................................................................... 364 Assembly.............................................................................................................. 364 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.......................................................................... 365 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE................................................................................. 367 AC DRIVE SYSTEM MAINTENANCE............................................................................................... 367 NORMAL TRUCK SHUTDOWN PROCEDURE........................................................................................... 368 SHUTDOWN AFTER SYSTEM FAILURE............................................................................................. 368 SYSTEM CHECKOUT........................................................................................................... 369 Battery and Control Circuit Checks - Battery Power OFF................................................................ 369 Battery and Control Circuit Checks - Battery Power ON................................................................. 372 Checks with Key Switch OFF............................................................................................ 373 Checks with Key Switch ON............................................................................................. 373 CPU Battery Checks.................................................................................................... 373 MEMORY BACKUP BATTERY REPLACEMENT......................................................................................... 374 TCI PROGRAMMING........................................................................................................... 374 PSC PROGRAMMING........................................................................................................... 375 INVERTER PROGRAMMING...................................................................................................... 375 CPU RESET................................................................................................................. 375 PSC CHECKOUT.............................................................................................................. 376 PSC Digital Input Checks.............................................................................................. 376 PSC Digital Output Checks............................................................................................. 380 TCI CHECKOUT.............................................................................................................. 381 Modular Mining Communication Port Check............................................................................... 381 TCI Digital Input Checks.............................................................................................. 381 TCI Digital Output Tests.............................................................................................. 387 CALIBRATIONS.............................................................................................................. 389 Speedometer........................................................................................................... 389 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial.................................................................. 389 ERASING EVENTS............................................................................................................ 389 PSC................................................................................................................... 389 TCI................................................................................................................... 390 GATE DRIVER POWER CONVERTER TEST.......................................................................................... 390 LOAD TESTING.............................................................................................................. 391 Preparation........................................................................................................... 391 Alternator Speed Sensor Checks........................................................................................ 391 Battery Boost Check................................................................................................... 391 Brake Circuit Switch Checks........................................................................................... 392 Hoist & Steering Circuit Switch Checks................................................................................ 392 Link Energized Checks................................................................................................. 392 Loadbox Test.......................................................................................................... 394 TROUBLESHOOTING........................................................................................................... 398 PVM Optimum Load Curve Handshaking Troubleshooting.................................................................... 398 Phase Module and Chopper Module Troubleshooting....................................................................... 398 PHASE MODULE REPLACEMENT.................................................................................................. 399 Phase Module Removal.................................................................................................. 399 Phase Module Installation............................................................................................. 399 SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146)................................................................................ 401 Fault Code A001: Left front suspension pressure sensor signal is high......................................................... 403 Related circuit diagram................................................................................................... 403 Fault Code A002: Left front suspension pressure sensor signal is low.......................................................... 404 Related circuit diagram................................................................................................... 404 Fault Code A003: Right front suspension pressure sensor signal is high........................................................ 405 Related circuit diagram................................................................................................... 405 Fault Code A004: Right front suspension pressure sensor signal is low......................................................... 406 Related circuit diagram................................................................................................... 406 Fault Code A005: Left rear suspension pressure sensor signal is high.......................................................... 407 Related circuit diagram................................................................................................... 407 Fault Code A006: Left rear suspension pressure sensor signal is low........................................................... 408 Related circuit diagram................................................................................................... 408 Fault Code A007: Right rear suspension pressure sensor signal is high......................................................... 409 Related circuit diagram................................................................................................... 409 Fault Code A008: Right rear suspension pressure sensor signal is low.......................................................... 410 Related circuit diagram................................................................................................... 410 Fault Code A009: Incline sensor signal is high................................................................................ 411 Related circuit diagram................................................................................................... 411 Fault Code A010: Incline sensor signal is low................................................................................. 412 Related circuit diagram................................................................................................... 412 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 413 Related circuit diagram................................................................................................... 413 Fault Code A013: Body up switch has failed.................................................................................... 414 Related circuit diagram................................................................................................... 414 Fault Code A014: Payload meter checksum computation has failed................................................................ 415 Related circuit diagram................................................................................................... 415 Fault Code A016: Payload meter write to flash memory has failed............................................................... 416 Related circuit diagram................................................................................................... 416 Fault Code A017: Payload meter flash memory read has failed................................................................... 417 Related circuit diagram................................................................................................... 417 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 418 Related circuit diagram................................................................................................... 419 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 420 Related circuit diagram................................................................................................... 421 Fault Code A022: Carryback load is excessive.................................................................................. 422 Related circuit diagram................................................................................................... 423 Fault Code A026: Payload meter user select switch has failed.................................................................. 424 Related circuit diagram................................................................................................... 424 Fault Code A027: Payload meter user clear switch has failed................................................................... 425 Related circuit diagram................................................................................................... 425 Fault Code A101: High pressure detected across a hydraulic pump filter........................................................ 426 Related circuit diagram................................................................................................... 427 Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level................................... 428 Related circuit diagram................................................................................................... 429 Fault Code A107: GE has generated a propel system caution..................................................................... 430 Related circuit diagram................................................................................................... 431 Fault Code A108: GE has generated a propel system temperature caution......................................................... 432 Related circuit diagram................................................................................................... 433 Fault Code A109: GE has generated a propel system reduced level signal........................................................ 434 Related circuit diagram................................................................................................... 435 Fault Code A115: Low steering precharge pressure is detected.................................................................. 436 Related circuit diagram................................................................................................... 437 Fault Code A123: GE has generated a reduced retarding caution................................................................. 438 Related circuit diagram................................................................................................... 439 Fault Code A124: GE has generated a no propel / no retard warning............................................................. 440 Related circuit diagram................................................................................................... 441 Fault Code A125: GE has generated a no propel warning......................................................................... 442 Related circuit diagram................................................................................................... 443 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 444 Related circuit diagram................................................................................................... 445 Fault Code A127: IM furnished +5 volt output for sensors is low............................................................... 446 Related circuit diagram................................................................................................... 447 Fault Code A128: IM furnished +5 volt output for sensors is high.............................................................. 448 Related circuit diagram................................................................................................... 449 Fault Code A139, A310: Low fuel level warning................................................................................. 450 Related circuit diagram................................................................................................... 451 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 452 Related circuit diagram................................................................................................... 453 Fault Code A146: Hydraulic temperature sensors cause posting of this faultl................................................... 454 Related circuit diagram................................................................................................... 455 SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216)................................................................................ 457 Fault Code A152: Starter failure.............................................................................................. 458 Related circuit diagram................................................................................................... 459 Fault Code A153: Battery voltage is low with truck in operation............................................................... 460 Related circuit diagram................................................................................................... 461 Fault Code A154: Battery charging voltage is excessive........................................................................ 462 Related circuit diagram................................................................................................... 463 Fault Code A155: Battery charging voltage is low.............................................................................. 464 Related circuit diagram................................................................................................... 465 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 466 Related circuit diagram................................................................................................... 467 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 468 Related circuit diagram................................................................................................... 469 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 470 Related circuit diagram................................................................................................... 471 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 472 Related circuit diagram................................................................................................... 473 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 474 Related circuit diagram................................................................................................... 475 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 476 Related circuit diagram................................................................................................... 476 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 477 Related circuit diagram................................................................................................... 477 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 478 Related circuit diagram................................................................................................... 478 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 479 Related circuit diagram................................................................................................... 479 Fault Code A184: J1939 data link is not connected............................................................................. 480 Related circuit diagram................................................................................................... 481 Fault Code A190: Auto lube control has detected an incomplete lube cycle...................................................... 482 Related circuit diagram................................................................................................... 483 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 484 Related circuit diagram................................................................................................... 485 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 486 Related circuit diagram....................................................................................................... 487 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 488 Related circuit diagram....................................................................................................... 489 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 490 Related circuit diagram....................................................................................................... 491 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 492 Related circuit diagram................................................................................................... 492 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 493 Related circuit diagram................................................................................................... 493 Fault Code A200: Steering pressure sensor is high............................................................................. 494 Related circuit diagram................................................................................................... 494 Fault Code A201: Brake pressure sensor is high................................................................................ 495 Related circuit diagram................................................................................................... 495 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 496 Related circuit diagram................................................................................................... 496 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 497 Related circuit diagram................................................................................................... 497 Fault Code A204: Steering pressure sensor is low.............................................................................. 498 Related circuit diagram................................................................................................... 498 Fault Code A205: Brake pressure sensor is low................................................................................. 499 Related circuit diagram................................................................................................... 499 Fault Code A206: Ambient temperature sensor is high........................................................................... 500 Related circuit diagram................................................................................................... 500 Fault Code A207: Ambient temperature sensor is low............................................................................ 501 Related circuit diagram................................................................................................... 501 Fault Code A212: Bad truck speed signal....................................................................................... 502 Related circuit diagram................................................................................................... 503 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 504 Related circuit diagram................................................................................................... 506 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 508 Related circuit diagram................................................................................................... 510 Fault Code A215: Brake auto apply relay circuit is defective.................................................................. 512 Related circuit diagram................................................................................................... 513 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 514 Related circuit diagram................................................................................................... 515 SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292)................................................................................ 517 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 518 Related circuit diagram................................................................................................... 519 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 520 Related circuit diagram................................................................................................... 521 Fault Code A236: Steering accumulator has not properly bled down after 90 seconds............................................. 522 Related circuit diagram................................................................................................... 523 Fault Code A240: The keyswitch input to the interface module is open.......................................................... 524 Related circuit diagram................................................................................................... 525 Fault Code A246: Payload meter reports truck overload......................................................................... 525 Related circuit diagram................................................................................................... 525 Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted............................... 526 Related circuit diagram................................................................................................... 527 Fault Code A250: Battery voltage is low with the truck parked................................................................. 528 Related circuit diagram................................................................................................... 529 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 530 Related circuit diagram................................................................................................... 531 Fault Code A253: Steering bleed circuit is not open while running............................................................. 532 Related circuit diagram................................................................................................... 533 Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open.................................. 534 Related circuit diagram................................................................................................... 535 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 536 Related circuit diagram................................................................................................... 536 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 538 Related circuit diagram................................................................................................... 539 Fault Code A260: Parking brake failure........................................................................................ 540 Related circuit diagram................................................................................................... 541 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 542 Related circuit diagram................................................................................................... 543 Fault Code A263: Steering bleed circuit is shorted to ground.................................................................. 544 Related circuit diagram................................................................................................... 545 Fault Code A264: Parking brake relay circuit is defective..................................................................... 546 Related circuit diagram................................................................................................... 547 Fault Code A265: Service brake failure........................................................................................ 548 Related circuit diagram................................................................................................... 550 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 552 Related circuit diagram................................................................................................... 553 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 554 Related circuit diagram................................................................................................... 556 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 558 Related circuit diagram................................................................................................... 559 Fault Code A274: A brake setting fault has been detected...................................................................... 560 Related circuit diagram................................................................................................... 561 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 562 Related circuit diagram................................................................................................... 563 Fault Code A276: The drive system data link is not connected.................................................................. 564 Related circuit diagram................................................................................................... 565 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 566 Related circuit diagram................................................................................................... 567 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................... 568 Related circuit diagram................................................................................................... 569 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated...................... 570 Related circuit diagram................................................................................................... 571 Fault Code A285: The parking brake was not set when the key switch was turned off............................................. 572 Related circuit diagram................................................................................................... 573 Fault Code A286: A fault was detected in the shutdown delay relay circuit..................................................... 574 Related circuit diagram................................................................................................... 575 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off......................... 576 Related circuit diagram................................................................................................... 577 SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365)................................................................................ 579 Fault Code A303: Shifter is defective......................................................................................... 580 Related circuit diagram................................................................................................... 581 Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be............ 582 Related circuit diagram................................................................................................... 583 Fault Code A309: No brakes applied when expected.............................................................................. 584 Related circuit diagram................................................................................................... 586 Fault Code A311: Brake lock switch is on when it should not be................................................................ 588 Related circuit diagram................................................................................................... 589 Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings............................................ 590 Related circuit diagram................................................................................................... 590 Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings........................................... 591 Related circuit diagram................................................................................................... 591 Fault Code A315: DC-DC converter 12 volt circuit is low....................................................................... 592 Related circuit diagram................................................................................................... 593 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 594 Related circuit diagram................................................................................................... 595 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 596 Related circuit diagram................................................................................................... 598 Fault Code A318: Unexpected power loss to interface module.................................................................... 599 Related circuit diagram................................................................................................... 599 Fault Code A328: Drive system not powered up.................................................................................. 600 Related circuit diagram................................................................................................... 601 Fault Code A350: Overload on output 1B........................................................................................ 602 Related circuit diagram................................................................................................... 603 Fault Code A351: Overload on output 1E........................................................................................ 604 Related circuit diagram................................................................................................... 605 Fault Code A352: Overload on output 1H........................................................................................ 606 Related circuit diagram................................................................................................... 607 Fault Code A353: Overload on output 1J........................................................................................ 608 Related circuit diagram................................................................................................... 609 Fault Code A354: Overload on output 1K........................................................................................ 610 Related circuit diagram................................................................................................... 611 Fault Code A355: Overload on output 1L........................................................................................ 612 Related circuit diagram................................................................................................... 613 Fault Code A356: Overload on output 1M........................................................................................ 614 Related circuit diagram................................................................................................... 615 Fault Code A357: Overload on output 1N........................................................................................ 616 Related circuit diagram................................................................................................... 617 Fault Code A358: Overload on output 1P........................................................................................ 618 Related circuit diagram................................................................................................... 619 Fault Code A359: Overload on output 1R........................................................................................ 620 Related circuit diagram................................................................................................... 621 Fault Code A360: Overload on output 1S........................................................................................ 622 Related circuit diagram................................................................................................... 623 Fault Code A361: Overload on output 1T........................................................................................ 624 Related circuit diagram................................................................................................... 625 Fault Code A362: Overload on output 1U........................................................................................ 626 Related circuit diagram................................................................................................... 627 Fault Code A363: Overload on output 1X........................................................................................ 628 Related circuit diagram................................................................................................... 628 Fault Code A364: Overload on output 1Y........................................................................................ 630 Related circuit diagram................................................................................................... 631 Fault Code A365: Overload on output 1Z........................................................................................ 632 Related circuit diagram................................................................................................... 633 SECTION G REAR AXLE, SPINDLES AND WHEELS.............................................................................................. 635 SECTION G2 TIRES AND RIMS......................................................................................................... 637 TIRES AND RIMS................................................................................................................ 639 WHEEL STUD MAINTENANCE.................................................................................................... 640 FRONT TIRES AND RIMS...................................................................................................... 641 Removal............................................................................................................... 641 Installation.......................................................................................................... 642 REAR TIRES AND RIMS....................................................................................................... 643 Removal............................................................................................................... 643 Installation.......................................................................................................... 644 RIM....................................................................................................................... 645 Tire Removal.......................................................................................................... 645 Tire Installation..................................................................................................... 645 SECTION G3 FRONT WHEEL HUB AND SPINDLE............................................................................................ 647 FRONT WHEEL HUB AND SPINDLE................................................................................................... 649 WHEEL HUB AND SPINDLE ASSEMBLY............................................................................................ 649 Removal............................................................................................................... 649 Spindle Removal Procedure (off of the truck).......................................................................... 652 Installation.......................................................................................................... 654 Disassembly........................................................................................................... 655 Cleaning and Inspection............................................................................................... 657 Assembly.............................................................................................................. 657 Wheel Bearing Adjustment.............................................................................................. 658 Brake Installation.................................................................................................... 659 Seal Assembly Gap Check............................................................................................... 660 WHEEL SPEED SENSOR TESTING................................................................................................ 661 STEERING CYLINDERS........................................................................................................ 662 Spherical Bearing Wear Limits......................................................................................... 662 Removal............................................................................................................... 663 Installation.......................................................................................................... 663 Bearing Replacement (Steering Cylinder and Tie Rod)................................................................... 663 TIE ROD................................................................................................................... 665 Removal............................................................................................................... 665 Installation.......................................................................................................... 665 Disassembly........................................................................................................... 666 Assembly.............................................................................................................. 666 Toe-In Adjustment..................................................................................................... 667 TIE ROD INSPECTION AND TORQUE PROCEDURE................................................................................... 668 Old Style Tie Rod..................................................................................................... 668 New Style Tie Rod..................................................................................................... 669 SECTION G4 REAR AXLE MOUNTING..................................................................................................... 671 REAR AXLE MOUNTING............................................................................................................ 673 PIVOT PIN................................................................................................................. 673 Removal............................................................................................................... 673 Installation.......................................................................................................... 674 PIVOT EYE BEARING......................................................................................................... 674 Removal............................................................................................................... 674 Installation.......................................................................................................... 674 PIVOT EYE REPAIR.......................................................................................................... 675 Removal............................................................................................................... 675 Installation.......................................................................................................... 675 ANTI-SWAY BAR............................................................................................................. 676 Removal............................................................................................................... 676 Disassembly........................................................................................................... 676 Cleaning and Inspection............................................................................................... 676 Assembly.............................................................................................................. 676 Installation.......................................................................................................... 676 SECTION G5 REAR AXLE AND WHEEL MOTOR.............................................................................................. 679 REAR AXLE AND WHEEL MOTOR..................................................................................................... 681 REAR AXLE HOUSING......................................................................................................... 681 Preparation........................................................................................................... 681 Removal............................................................................................................... 682 Cleaning and Inspection............................................................................................... 683 Installation.......................................................................................................... 683 BLOWER PRESSURE SWITCH ADJUSTMENT......................................................................................... 683 WHEEL MOTOR............................................................................................................... 684 Preparation........................................................................................................... 684 Removal............................................................................................................... 685 Cleaning and Inspection............................................................................................... 687 Installation.......................................................................................................... 687 WHEEL MOTOR GEAR OIL...................................................................................................... 692 Filtering Requirements................................................................................................ 692 Particle Size Analysis................................................................................................ 692 Flushing.............................................................................................................. 692 Oil Sample Analysis................................................................................................... 693 ELEMENT SPECIFICATION CHARTS.............................................................................................. 694 SECTION H HYDRAIR® II SUSPENSIONS..................................................................................................... 697 SECTION H2 FRONT SUSPENSIONS...................................................................................................... 699 FRONT SUSPENSION.............................................................................................................. 701 Removal................................................................................................................... 701 Installation.............................................................................................................. 702 Inspection................................................................................................................ 707 LOWER BEARING & SEALS..................................................................................................... 708 Removal............................................................................................................... 708 Installation.......................................................................................................... 708 MAJOR SUSPENSION REBUILD.................................................................................................. 709 Disassembly........................................................................................................... 709 Assembly.............................................................................................................. 710 SUSPENSION PRESSURE TEST.................................................................................................. 711 SECTION H3 REAR SUSPENSIONS....................................................................................................... 713 REAR SUSPENSIONS.............................................................................................................. 715 SUSPENSION CYLINDER....................................................................................................... 716 Removal............................................................................................................... 716 Installation.......................................................................................................... 718 Disassembly........................................................................................................... 718 Cleaning and Inspection............................................................................................... 719 Assembly.............................................................................................................. 719 SUSPENSION PRESSURE TEST.................................................................................................. 721 SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES.............................................................................. 723 SUSPENSION OILING AND CHARGING PROCEDURE...................................................................................... 725 GENERAL................................................................................................................... 725 EQUIPMENT LIST............................................................................................................ 725 HYDRAIR® CHARGING KIT..................................................................................................... 726 Installation of Charging Kit.......................................................................................... 726 Removal of Charging Kit............................................................................................... 726 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS......................................................................... 727 FRONT SUSPENSION.......................................................................................................... 727 Front Suspension Oiling............................................................................................... 727 Front Suspension Nitrogen Charging.................................................................................... 729 REAR SUSPENSION........................................................................................................... 730 Rear Suspension Oiling................................................................................................ 731 Rear Suspension Nitrogen Charging..................................................................................... 733 OIL AND NITROGEN SPECIFICATIONS CHARTS........................................................................................ 734 SECTION J BRAKE CIRCUIT............................................................................................................... 735 SECTION J2 BRAKE CIRCUIT.......................................................................................................... 737 BRAKE CIRCUIT................................................................................................................. 739 SERVICE BRAKE CIRCUIT..................................................................................................... 739 PARKING BRAKE CIRCUIT..................................................................................................... 741 BRAKE LOCK CIRCUIT........................................................................................................ 741 SECONDARY BRAKING AND AUTOMATIC APPLY..................................................................................... 742 WARNING CIRCUIT........................................................................................................... 742 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE........................................................................................ 745 BRAKE CIRCUIT COMPONENT SERVICE............................................................................................... 747 BRAKE VALVE............................................................................................................... 747 Rebuild Criteria...................................................................................................... 747 Removal............................................................................................................... 748 Installation.......................................................................................................... 748 Disassembly........................................................................................................... 749 Cleaning and Inspection............................................................................................... 752 Assembly.............................................................................................................. 752 Regulator Sleeve O-Ring Installation.................................................................................. 753 BRAKE VALVE BENCH TEST AND ADJUSTMENT..................................................................................... 755 Test Setup Procedure.................................................................................................. 756 Brake Valve Output Pressure Adjustment................................................................................ 756 Final Test and Adjustment............................................................................................. 757 Installing Brake Pedal Actuator Assembly to Brake Valve............................................................... 757 Installing Retard Pedal To Brake Pedal................................................................................ 757 DUAL RELAY VALVE.......................................................................................................... 758 Removal............................................................................................................... 758 Installation.......................................................................................................... 758 Disassembly........................................................................................................... 758 Cleaning and Inspection............................................................................................... 759 Assembly.............................................................................................................. 760 DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT................................................................................ 761 Test Setup Procedure.................................................................................................. 762 Relay Valve Output Pressure Adjustment................................................................................ 762 BRAKE MANIFOLD............................................................................................................ 763 Removal............................................................................................................... 763 Installation.......................................................................................................... 763 Disassembly........................................................................................................... 763 Cleaning and Inspection............................................................................................... 764 Assembly.............................................................................................................. 764 BRAKE ACCUMULATORS........................................................................................................ 764 Brake Accumulator Bleeddown Procedure................................................................................. 764 Removal............................................................................................................... 765 Installation.......................................................................................................... 765 Disassembly........................................................................................................... 766 Cleaning and Inspection............................................................................................... 767 Assembly.............................................................................................................. 767 Accumulator Charging Procedure........................................................................................ 769 Precharge Maintenance................................................................................................. 771 Accumulator Storage Procedures........................................................................................ 772 Bladder Storage Procedures............................................................................................ 772 Installing A Bladder Accumulator From Storage......................................................................... 772 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................................................... 773 Removal............................................................................................................... 773 Installation.......................................................................................................... 773 Disassembly........................................................................................................... 773 Lever Adjustments..................................................................................................... 773 Potentiometer Check................................................................................................... 774 Assembly.............................................................................................................. 774 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE...................................................................................... 777 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................................................. 779 REQUIRED EQUIPMENT........................................................................................................ 780 INITIAL SYSTEM SETUP...................................................................................................... 781 BRAKE LOCK / SECONDARY BRAKE CHECK-OUT.................................................................................... 782 PARKING BRAKE CHECK-OUT................................................................................................... 783 SERVICE BRAKE CHECK-OUT................................................................................................... 784 LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT......................................................................... 785 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART........................................................................... 786 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET......................................................................... 788 SECTION J5 WET DISC BRAKE ASSEMBLY................................................................................................ 791 WET DISC BRAKE ASSEMBLY....................................................................................................... 793 OPERATION................................................................................................................. 793 BRAKE DISC WEAR INSPECTION................................................................................................ 794 BRAKE REBUILD............................................................................................................. 795 Disassembly........................................................................................................... 795 Cleaning and Inspection............................................................................................... 799 Assembly.............................................................................................................. 800 Floating Ring Seal Assembly & Installation............................................................................ 805 WET DISC BRAKE BLEEDING PROCEDURE......................................................................................... 809 SECTION J7 PARKING BRAKE.......................................................................................................... 811 PARKING BRAKE................................................................................................................. 813 OPERATION................................................................................................................. 813 MAINTENANCE............................................................................................................... 814 Inspection............................................................................................................ 814 Removal............................................................................................................... 814 Installation.......................................................................................................... 815 Disassembly........................................................................................................... 815 Cleaning and Inspection............................................................................................... 815 Assembly.............................................................................................................. 817 Cleaning and Inspecting New Discs..................................................................................... 818 PARKING BRAKE BLEEDING PROCEDURE.......................................................................................... 819 SECTION L HYDRAULIC SYSTEM............................................................................................................ 821 SECTION L2 HYDRAULIC SYSTEM....................................................................................................... 823 HYDRAULIC SYSTEM.............................................................................................................. 825 HYDRAULIC PUMP MODULE..................................................................................................... 825 HOIST CIRCUIT OPERATION................................................................................................... 826 STEERING CIRCUIT OPERATION................................................................................................ 828 DISC BRAKE COOLING SYSTEM................................................................................................. 830 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR...................................................................................... 833 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................................................. 835 HOIST PUMP................................................................................................................ 835 Removal............................................................................................................... 835 Installation.......................................................................................................... 837 Inspection............................................................................................................ 842 Assembly.............................................................................................................. 842 HYDRAULIC TANK............................................................................................................ 848 Removal............................................................................................................... 848 Installation.......................................................................................................... 849 HYDRAULIC TANK BREATHERS.................................................................................................. 849 HYDRAULIC TANK STRAINERS.................................................................................................. 850 Removal............................................................................................................... 850 Inspect and Clean..................................................................................................... 850 Installation.......................................................................................................... 850 SECTION L4 STEERING CIRCUIT....................................................................................................... 851 STEERING CIRCUIT.............................................................................................................. 853 STEERING CIRCUIT OPERATION................................................................................................ 853 COMPONENT DESCRIPTION..................................................................................................... 854 Steering Control Unit................................................................................................. 854 Bleeddown Manifold.................................................................................................... 855 Steering Accumulator Bleed Down Solenoid.............................................................................. 855 Relief Valves......................................................................................................... 857 Hoist Up Limit Solenoid............................................................................................... 857 Steering Accumulators................................................................................................. 857 Low Precharge Warning Switch.......................................................................................... 857 High Pressure Filter.................................................................................................. 857 Quick Disconnect Ports................................................................................................ 857 Flow Amplifier........................................................................................................ 859 FLOW AMPLIFIER SYSTEM OPERATION........................................................................................... 860 No Steer.............................................................................................................. 860 Steering Left......................................................................................................... 862 Steering Right........................................................................................................ 864 No Steer, External Shock Load......................................................................................... 866 STEERING PUMP............................................................................................................. 868 Normal Operation...................................................................................................... 868 PRINCIPLE OF OPERATION.................................................................................................... 870 Full Pump Volume...................................................................................................... 870 Half Pump Volume...................................................................................................... 870 Neutral Position...................................................................................................... 870 Steering Pump......................................................................................................... 871 SECTION L5 STEERING CONTROL UNIT.................................................................................................. 873 STEERING CONTROL UNIT......................................................................................................... 875 REMOVAL................................................................................................................... 875 SPLINE INSPECTION......................................................................................................... 875 INSTALLATION.............................................................................................................. 876 DISASSEMBLY............................................................................................................... 876 CLEANING AND INSPECTION................................................................................................... 877 ASSEMBLY.................................................................................................................. 879 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR...................................................................................... 883 STEERING CIRCUIT COMPONENT REPAIR............................................................................................. 885 BLEEDDOWN MANIFOLD VALVE.................................................................................................. 885 Removal............................................................................................................... 885 Installation.......................................................................................................... 886 FLOW AMPLIFIER............................................................................................................ 887 Removal............................................................................................................... 887 Installation.......................................................................................................... 887 Disassembly........................................................................................................... 887 Assembly.............................................................................................................. 889 STEERING CYLINDERS........................................................................................................ 890 Disassembly........................................................................................................... 891 Piston Seal & Bearing Installation.................................................................................... 891 Assembly.............................................................................................................. 891 Testing............................................................................................................... 891 STEERING AND BRAKE PUMP................................................................................................... 892 Removal............................................................................................................... 892 Installation.......................................................................................................... 893 Disassembly........................................................................................................... 894 Inspection............................................................................................................ 897 Assembly.............................................................................................................. 900 Driveshaft Group...................................................................................................... 901 Rotating Group........................................................................................................ 901 Valve Plate Group..................................................................................................... 902 STEERING ACCUMULATORS..................................................................................................... 904 Removal............................................................................................................... 904 Installation.......................................................................................................... 904 Disassembly........................................................................................................... 905 Cleaning and Inspection............................................................................................... 905 Assembly.............................................................................................................. 906 Leak Testing.......................................................................................................... 908 Charging Procedure.................................................................................................... 909 Precharge Maintenance................................................................................................. 911 Accumulator Storage Procedures........................................................................................ 912 Bladder Storage Procedures............................................................................................ 912 Installing A Bladder Accumulator From Storage......................................................................... 912 TROUBLESHOOTING CHART......................................................................................................... 913 SECTION L7 HOIST CIRCUIT.......................................................................................................... 917 HOIST CIRCUIT................................................................................................................. 919 BASIC OPERATION........................................................................................................... 919 COMPONENT DESCRIPTION..................................................................................................... 920 Hydraulic Tank........................................................................................................ 920 Hydraulic Pump........................................................................................................ 920 High Pressure Filters................................................................................................. 920 Hoist Valve........................................................................................................... 920 Inlet Sections........................................................................................................ 920 Work Ports (Rear) Spool Section....................................................................................... 921 Tank Ports (Front) Spool Section...................................................................................... 921 Hoist Pilot Valve..................................................................................................... 921 Bleeddown Manifold.................................................................................................... 922 Hoist Up Limit Solenoid............................................................................................... 922 Pilot Operated Check Valve............................................................................................ 922 Overcenter Manifold................................................................................................... 922 HOIST CIRCUIT OPERATION....................................................................................................... 923 Float Position Of Pilot Valve With Truck Body On Frame.................................................................... 924 Power Up Operation........................................................................................................ 926 Hold Operation............................................................................................................ 928 Power Down Operation...................................................................................................... 930 Float Operation........................................................................................................... 932 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR......................................................................................... 935 HOIST CIRCUIT COMPONENT REPAIR................................................................................................ 937 HOIST VALVE............................................................................................................... 937 Removal............................................................................................................... 937 Installation.......................................................................................................... 938 O-Ring Replacement.................................................................................................... 938 INLET SECTION............................................................................................................. 939 Disassembly........................................................................................................... 939 Cleaning and Inspection............................................................................................... 940 Assembly.............................................................................................................. 940 REAR SPOOL SECTION (Work Ports)........................................................................................... 941 Disassembly........................................................................................................... 941 Cleaning and Inspection............................................................................................... 941 Assembly.............................................................................................................. 943 FRONT SPOOL SECTION (Tank Ports).......................................................................................... 944 Disassembly........................................................................................................... 944 Cleaning and Inspection............................................................................................... 944 Assembly.............................................................................................................. 944 HOIST PILOT VALVE......................................................................................................... 946 Removal............................................................................................................... 946 Installation.......................................................................................................... 946 Disassembly........................................................................................................... 947 Cleaning and Inspection............................................................................................... 948 Assembly.............................................................................................................. 948 HOIST CYLINDERS........................................................................................................... 949 Removal............................................................................................................... 949 Installation.......................................................................................................... 950 Disassembly........................................................................................................... 952 Cleaning and Inspection............................................................................................... 953 Assembly - Quill...................................................................................................... 954 Assembly - Cylinder................................................................................................... 956 Testing............................................................................................................... 956 OVERCENTER VALVE MANIFOLD................................................................................................. 957 SECTION L9 HYDRAULIC SYSTEM FILTERS............................................................................................... 959 HYDRAULIC SYSTEM FILTERS...................................................................................................... 961 HOIST CIRCUIT FILTER...................................................................................................... 961 Filter Element Replacement............................................................................................ 961 Removal - Hoist Circuit Filter........................................................................................ 962 Installation - Hoist Circuit Filter................................................................................... 962 Indicator Switch - Hoist Circuit Filter............................................................................... 962 STEERING CIRCUIT FILTER................................................................................................... 963 Filter Element Replacement............................................................................................ 963 Removal - Steering Circuit Filter..................................................................................... 964 Installation - Steering Circuit Filter................................................................................ 964 Indicator Switch - Steering Circuit Filter............................................................................ 964 INDICATOR SWITCH.......................................................................................................... 964 Test Procedure........................................................................................................ 964 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE.......................................................................................... 967 HYDRAULIC CHECKOUT PROCEDURE.................................................................................................. 969 GENERAL INFORMATION....................................................................................................... 969 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................................................... 976 Equipment Requirements................................................................................................ 977 Pump Pressure Control Adjustments..................................................................................... 977 Steering Control Valve and Flow Amplifier Leakage Test................................................................ 978 Bleeddown Manifold Leakage Test....................................................................................... 979 STEERING/BRAKE PUMP STROKE ADJUSTMENT..................................................................................... 980 SHOCK AND SUCTION VALVES.................................................................................................. 980 Equipment Requirements................................................................................................ 980 Pressure Tests........................................................................................................ 980 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES............................................................. 982 Equipment Requirements................................................................................................ 982 Pressure Gauge Locations.............................................................................................. 982 Brake Cooling Circuit Test............................................................................................ 982 Power Up Relief Pressure Test......................................................................................... 983 Power Down Relief Pressure Test....................................................................................... 984 Counterbalance Valve Pressure Check................................................................................... 985 Counterbalance Valve Adjustment....................................................................................... 986 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET......................................................................... 987 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET............................................................ 988 SECTION M OPTIONS AND SPECIAL TOOLS................................................................................................... 989 SECTION M7 HOT START SYSTEM....................................................................................................... 991 HOT START SYSTEM.............................................................................................................. 993 SYSTEM OPERATION.......................................................................................................... 993 HEATER INFORMATION........................................................................................................ 994 TROUBLESHOOTING GUIDELINES................................................................................................ 995 SECTION M8 SPECIAL TOOLS.......................................................................................................... 997 HIGH VOLTAGE TOOLS............................................................................................................1002 0-2000 VDC CUSTOM METER KIT (58B-06-00800)....................................................................................1002 SECTION M19 RADIATOR SHUTTERS.....................................................................................................1005 RADIATOR SHUTTERS.............................................................................................................1007 OPERATION.................................................................................................................1007 Hydraulic Circuit.....................................................................................................1007 Electrical Circuit....................................................................................................1008 MAINTENANCE AND REPAIR....................................................................................................1008 TROUBLESHOOTING...........................................................................................................1009 SECTION M20 PAYLOAD METER III ™...................................................................................................1013 OPERATION SECTION.............................................................................................................1017 Introduction..............................................................................................................1017 Data Summary..........................................................................................................1017 Data Gathering........................................................................................................1017 COMPONENT DESCRIPTION.....................................................................................................1018 System Diagram........................................................................................................1018 Suspension Pressure Sensors...........................................................................................1018 Inclinometer..........................................................................................................1018 Operator Display......................................................................................................1018 Operator Switch.......................................................................................................1019 Speed Input...........................................................................................................1019 Body-Up Switch........................................................................................................1019 Brake Lock Switch.....................................................................................................1019 Payload Meter.........................................................................................................1019 Communications Ports..................................................................................................1019 Key Switch Input......................................................................................................1020 Payload Meter Power...................................................................................................1020 Load Lights...........................................................................................................1020 Wiring and Termination................................................................................................1021 TCI Outputs...........................................................................................................1021 OPERATOR’S DISPLAY AND SWITCH.............................................................................................1022 Reading the Speedometer...............................................................................................1022 Reading the Load Display..............................................................................................1022 Using the Operator ID.................................................................................................1022 Using the Load and Ton Counter........................................................................................1022 Total Ton Counter.....................................................................................................1022 Total Load Counter....................................................................................................1023 Clearing the Counters.................................................................................................1023 Viewing Live Sensor Data..............................................................................................1023 Other Display Messages................................................................................................1023 PAYLOAD OPERATION & CALCULATION...........................................................................................1024 Description of Haul Cycle States......................................................................................1024 Haul Cycle Description................................................................................................1024 Load Calculation......................................................................................................1025 Carry Back............................................................................................................1025 Measurement Accuracy..................................................................................................1025 SOURCES FOR PAYLOAD ERROR.................................................................................................1025 Payload Error.........................................................................................................1025 Loading Conditions....................................................................................................1026 Pressure Sensors......................................................................................................1026 Swingloads............................................................................................................1026 Speed and Distance....................................................................................................1026 HAUL CYCLE DATA...........................................................................................................1026 Haul Cycle Warning Flags..............................................................................................1028 Frame Torque Data.....................................................................................................1029 Sprung Weight Data....................................................................................................1029 Maximum Speed Data....................................................................................................1029 Alarm Records.........................................................................................................1029 Fault Code Data.......................................................................................................1030 PC SOFTWARE OVERVIEW......................................................................................................1031 System Configuration..................................................................................................1031 Installing the PLMIII Software........................................................................................1031 DOWNLOADING DATA..........................................................................................................1032 PLM III SYSTEM CONFIGURATION..............................................................................................1033 Starting Communications...............................................................................................1033 Displayed Payload Units...............................................................................................1033 Time Units............................................................................................................1033 Connection Menu.......................................................................................................1033 Connecting to the Payload Meter.......................................................................................1034 Configure the Payload Meter...........................................................................................1034 Setting the Date and Time.............................................................................................1034 Setting the Truck Type................................................................................................1035 Setting the Gauge Display Units.......................................................................................1035 Setting the Frame Serial Number.......................................................................................1035 Setting the Truck Number..............................................................................................1035 Setting the Komatsu Distributor.......................................................................................1035 Setting the Komatsu Customer..........................................................................................1035 Clean Truck Tare Calibration..........................................................................................1036 Inclinometer Calibration..............................................................................................1036 DATA ANALYSIS.............................................................................................................1037 Creating a Query......................................................................................................1037 Sorting on Truck Unit Number..........................................................................................1037 Sorting on Truck Type.................................................................................................1037 Sorting on Date Range.................................................................................................1038 Sorting on Time Range.................................................................................................1038 Payload Detail Screen.................................................................................................1039 Creating Reports......................................................................................................1039 Summary - one page report.............................................................................................1040 Detailed - multi-page report..........................................................................................1040 Creating Graphs.......................................................................................................1041 Exporting Data........................................................................................................1041 CSV Export............................................................................................................1041 Compressed............................................................................................................1042 Importing Data........................................................................................................1043 Deleting Haul Cycle Records...........................................................................................1043 Viewing Alarms........................................................................................................1044 Deleting Alarm Records................................................................................................1044 TROUBLESHOOTING SECTION.......................................................................................................1045 TROUBLESHOOTING...........................................................................................................1045 Viewing Active Alarms.................................................................................................1045 Real-Time Data Display................................................................................................1045 Testing the Payload Lights............................................................................................1045 Creating Log Files of Inputs..........................................................................................1046 Daily Inspections.....................................................................................................1046 Periodic Maintenance..................................................................................................1046 Abnormal Displays at Power-Up.........................................................................................1047 No Payload Display When Key Switch is Turned ON.......................................................................1048 No Display on Speedometer.............................................................................................1049 No Display on Operator Display........................................................................................1049 No Communications With PC.............................................................................................1050 Load Lights Don’t Light During Loading................................................................................1051 Load Lights Remain ON.................................................................................................1052 Load Lights Remain ON During Dumping..................................................................................1052 Display Doesn't Clear When The Load Is Dumped.........................................................................1052 Calibration Problems..................................................................................................1053 Alarm 1 - Left Front Pressure High....................................................................................1054 Alarm 2 - Left Front Pressure Low.....................................................................................1054 Troubleshoot Wiring to Left Front Suspension..........................................................................1054 Alarm 3 - Right Front Pressure High...................................................................................1055 Alarm 4 - Right Front Pressure Low....................................................................................1055 Troubleshoot Wiring to Right Front Suspension.........................................................................1055 Alarm 5 -Left Rear Pressure High......................................................................................1056 Alarm 6 - Left Rear Pressure Low......................................................................................1056 Troubleshoot Wiring to Left Rear Suspension...........................................................................1056 Alarm 7 - Right Rear Pressure High....................................................................................1057 Alarm 8 - Right Rear Pressure Low.....................................................................................1057 Troubleshoot Wiring to Right Rear Suspension..........................................................................1057 Alarm 9 - Inclinometer High...........................................................................................1058 Alarm 10 - Inclinometer Low...........................................................................................1058 Troubleshoot Inclinometer Wiring......................................................................................1058 Alarm 13 - Body Up Input Failure......................................................................................1059 Alarm 16 - Memory Write Failure.......................................................................................1060 Alarm 17 - Memory Read Failure........................................................................................1060 Alarm 18..............................................................................................................1061 Alarm 19..............................................................................................................1061 Alarm 22..............................................................................................................1061 Operator Switch Doesn't Work..........................................................................................1062 Alarm 26 - User Switch Fault - SELECT.................................................................................1062 Alarm 27 - User Switch Fault - SET....................................................................................1062 Connector Map.........................................................................................................1063 Connectors............................................................................................................1064 PLMIII CHECK OUT PROCEDURE....................................................................................................1065 General Description.......................................................................................................1065 Tools Required............................................................................................................1065 Checkout Procedure........................................................................................................1065 PLMIII CHECKOUT PROCEDURE CONFIRMATION....................................................................................1069 Flashburn Programming.................................................................................................1069 Confirmation Checklist................................................................................................1071 SECTION M31 RESERVE ENGINE OIL SYSTEM.............................................................................................1073 RESERVE ENGINE OIL SYSTEM.....................................................................................................1075 Operation.................................................................................................................1076 LED Monitor Light.........................................................................................................1076 Tank Fill Control (Optional)..............................................................................................1077 Filling Procedure (Remote Fill Feature)...................................................................................1077 SERVICE...................................................................................................................1078 Every 10 Hours, or once each shift:...................................................................................1078 Every 500 Hours.......................................................................................................1078 Changing Oil..........................................................................................................1078 TROUBLESHOOTING...........................................................................................................1079 Circuit Fuse..........................................................................................................1079 SYSTEM ELECTRICAL SCHEMATICS..............................................................................................1080 SECTION N OPERATOR CAB................................................................................................................1081 SECTION N2 TRUCK CAB AND COMPONENTS...............................................................................................1083 TRUCK CAB AND COMPONENTS......................................................................................................1085 TRUCK CAB.................................................................................................................1085 Description...........................................................................................................1085 Removal...............................................................................................................1086 Installation..........................................................................................................1087 CAB DOOR..................................................................................................................1088 Removal...............................................................................................................1088 Installation..........................................................................................................1088 Door Jamb Bolt Adjustment.............................................................................................1089 Door Handle Plunger Adjustment........................................................................................1090 Replacing the Door Glass..............................................................................................1091 Replacing the Door Handle or Latch Assembly...........................................................................1095 Replacing the Door Window Regulator...................................................................................1096 Replacing the Door and Door Hinge Seal................................................................................1097 Replacing the Door Opening Seal.......................................................................................1097 GLASS REPLACEMENT (Adhesive-Bonded Windows)...............................................................................1098 Recommended Tools and Supplies........................................................................................1098 Replacement Procedure.................................................................................................1098 WINDSHIELD AND REAR GLASS.................................................................................................1099 Removal...............................................................................................................1099 Installation..........................................................................................................1100 SECTION N3 CAB COMPONENTS.........................................................................................................1101 CAB COMPONENTS................................................................................................................1103 WINDSHIELD WIPERS.........................................................................................................1103 WIPER MOTOR...........................................................................................................1103 Removal...........................................................................................................1103 Installation......................................................................................................1103 WIPER ARM.............................................................................................................1103 Removal...........................................................................................................1103 Installation......................................................................................................1104 WIPER LINKAGE.........................................................................................................1104 Removal...........................................................................................................1104 Installation......................................................................................................1104 WINDSHIELD WASHER.........................................................................................................1105 Operation.............................................................................................................1105 Service...............................................................................................................1105 OPERATOR SEAT.............................................................................................................1106 Adjustment............................................................................................................1106 Inspection............................................................................................................1107 Removal...............................................................................................................1107 Installation..........................................................................................................1107 PASSENGER SEAT............................................................................................................1108 Inspection............................................................................................................1108 Removal...............................................................................................................1108 Installation..........................................................................................................1108 SEAT BELT.................................................................................................................1109 Removal...............................................................................................................1109 Installation..........................................................................................................1109 SECTION N4 HEATER / AIR CONDITIONER...............................................................................................1111 HEATER/AIR CONDITIONER........................................................................................................1113 OPERATION.................................................................................................................1113 Fan Speed Control Knob................................................................................................1113 Temperature Control Knob..............................................................................................1113 Air Flow Directional Knob.............................................................................................1114 Heater/Air Conditioner Vents..........................................................................................1114 COMPONENTS................................................................................................................1114 Fuse and Circuit Breaker..............................................................................................1114 Relays................................................................................................................1114 Heater Core...........................................................................................................1115 Fan Motor And Speed Control...........................................................................................1115 Actuators.............................................................................................................1115 Cab Air Filter........................................................................................................1115 ENVIRONMENTAL IMPACT OF AIR CONDITIONING..................................................................................1118 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.................................................................................1118 PRINCIPLES OF REFRIGERATION...............................................................................................1118 Air Conditioning......................................................................................................1118 Refrigeration - The Act Of Cooling....................................................................................1119 The Refrigeration Cycle...............................................................................................1119 AIR CONDITIONER SYSTEM COMPONENTS.........................................................................................1120 Compressor (Refrigerant Pump).........................................................................................1120 Service Valves........................................................................................................1120 Condenser.............................................................................................................1120 Receiver-Drier........................................................................................................1120 Expansion Block Valve.................................................................................................1121 Accumulator...........................................................................................................1121 Evaporator............................................................................................................1121 ELECTRICAL CIRCUIT........................................................................................................1122 Thermostat............................................................................................................1122 Compressor Clutch.....................................................................................................1122 Trinary™ Switch.......................................................................................................1123 AIR CONDITIONING SYSTEM SERVICING WARNINGS................................................................................1124 SERVICE TOOLS AND EQUIPMENT...............................................................................................1125 Recovery/Recycle Station..............................................................................................1125 Leak Detector.........................................................................................................1125 Manifold Gauge Set....................................................................................................1126 Installing Manifold Gauge Set.........................................................................................1127 Purging Air From Service Hoses........................................................................................1127 Service Valves........................................................................................................1128 Vacuum Pump...........................................................................................................1128 SYSTEM PERFORMANCE TEST...................................................................................................1129 SYSTEM OIL................................................................................................................1130 Handling and Reusing PAG Oil..........................................................................................1130 Oil Quantity..........................................................................................................1130 Checking System Oil...................................................................................................1130 REFRIGERANT...............................................................................................................1131 Recycled Refrigerant..................................................................................................1131 Reclaimed Refrigerant.................................................................................................1131 Refrigerant Quantity..................................................................................................1132 R-134a Refrigerant Containers.........................................................................................1132 SYSTEM LEAK TESTING.......................................................................................................1132 Electronic Leak Detector..............................................................................................1133 Tracer Dyes...........................................................................................................1133 Soap and Water........................................................................................................1133 RECOVERING AND RECYCLING THE REFRIGERANT..................................................................................1133 Draining Oil from the Previous Recovery Cycle.........................................................................1133 Performing the Recovery Cycle.........................................................................................1133 Performing the Recycling Procedure....................................................................................1134 Evacuating and Charging the A/C System................................................................................1134 SYSTEM REPAIR.............................................................................................................1134 System Flushing.......................................................................................................1134 A/C DRIVE BELT CHECKOUT PROCEDURE.........................................................................................1135 Pulley Alignment......................................................................................................1135 Belt Tension Check....................................................................................................1135 COMPONENT REPLACEMENT.....................................................................................................1137 Hoses and Fittings....................................................................................................1137 Lines.................................................................................................................1137 Expansion Valve.......................................................................................................1137 Receiver-Drier........................................................................................................1137 Thermostat............................................................................................................1137 Compressor............................................................................................................1138 Accumulator...........................................................................................................1138 Clutch................................................................................................................1138 Servicing the Compressor Clutch.......................................................................................1139 Pulley Removal........................................................................................................1141 Clutch Coil Check.....................................................................................................1141 Pulley Installation...................................................................................................1141 Clutch Assembly Installation..........................................................................................1142 EVACUATING THE SYSTEM.....................................................................................................1143 CHARGING THE A/C SYSTEM...................................................................................................1144 TROUBLESHOOTING...........................................................................................................1145 Preliminary Checks....................................................................................................1145 Diagnosis Of Gauge Readings And System Performance....................................................................1145 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................................................................1146 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM................................................................................1152 SECTION N5 OPERATOR CAB AND CONTROLS..............................................................................................1153 OPERATOR CAB AND CONTROLS.....................................................................................................1156 STEERING COLUMN...........................................................................................................1157 Removal...............................................................................................................1157 Inspection............................................................................................................1157 Installation..........................................................................................................1158 STEERING WHEEL............................................................................................................1158 Removal...............................................................................................................1158 Installation..........................................................................................................1158 STEERING WHEEL AND CONTROLS...............................................................................................1160 Horn Button...........................................................................................................1160 Tilt / Telescope Lever................................................................................................1160 Multi-Function Turn Signal Switch.....................................................................................1160 DYNAMIC RETARDING.........................................................................................................1161 Retarder Lever........................................................................................................1161 Brake/Retarder Pedal..................................................................................................1161 Throttle/Accelerator Pedal............................................................................................1161 GRADE/SPEED CHART.........................................................................................................1162 OVERHEAD PANEL AND DISPLAYS...............................................................................................1163 CENTER CONSOLE............................................................................................................1164 Directional Control Lever.............................................................................................1164 Override/Fault Reset Switch...........................................................................................1165 Engine Shutdown Switch................................................................................................1165 Window Control Switches...............................................................................................1165 Hoist Control Lever...................................................................................................1165 Retarder Speed Control (RSC) Adjustment Dial..........................................................................1166 Retarder Speed Control (RSC) Switch...................................................................................1166 Data Store Button.....................................................................................................1167 KOMTRAX Plus Snapshot In Progress Light...............................................................................1167 Link Energized Light..................................................................................................1167 Service Engine Light..................................................................................................1167 12V Auxiliary Power Outlets...........................................................................................1167 Fire Suppression Control Outlet.......................................................................................1167 Communication Radio Outlet............................................................................................1167 DIAGNOSTIC PORTS..........................................................................................................1167 KOMTRAX Plus Diagnostic Port..........................................................................................1167 Interface Module (IM) Diagnostic Port.................................................................................1167 Payload Meter Diagnostic Port.........................................................................................1167 Truck Control Interface (TCI) Diagnostic Port.........................................................................1167 Propulsion System Controller (PSC) Diagnostic Port....................................................................1167 Engine Diagnostic Port (CENSE)........................................................................................1167 Engine Diagnostic Port (QUANTUM)......................................................................................1167 INSTRUMENT PANEL..........................................................................................................1168 Control Symbols.......................................................................................................1168 Key Switch............................................................................................................1170 Rotating Beacon Light Switch (optional)...............................................................................1170 Heated Mirror Switch (optional).......................................................................................1170 AC Drive System Rest Switch...........................................................................................1170 Wheel Brake Lock Switch...............................................................................................1171 Hazard Warning Light Switch...........................................................................................1171 Heater/Air Conditioner Vents..........................................................................................1171 Engine Oil Pressure Gauge.............................................................................................1171 Right Turn Signal Indicator...........................................................................................1171 Digital Tachometer....................................................................................................1171 High Beam Indicator...................................................................................................1171 Speedometer/Payload Meter Display.....................................................................................1171 Left Turn Signal Indicator............................................................................................1172 Coolant Temperature Gauge.............................................................................................1172 Lamp Check Switch.....................................................................................................1172 Light Switch (3-Way)..................................................................................................1172 Ladder Light Switch...................................................................................................1172 Backup Light Switch...................................................................................................1172 Fog Light Switch......................................................................................................1173 Payload Meter Switch..................................................................................................1173 Panel Illumination Light Dimmer Switch................................................................................1173 Hydraulic Oil Temperature Gauge.......................................................................................1173 Engine Hourmeter......................................................................................................1173 Fuel Gauge............................................................................................................1173 OVERHEAD STATUS / WARNING INDICATORS......................................................................................1174 A1. High Brake Oil Temperature........................................................................................1175 B1. Low Steering Pressure.............................................................................................1175 C1. Low Accumulator Precharge Pressure................................................................................1176 D1. Not used..........................................................................................................1176 E1. Low Brake Pressure................................................................................................1176 A2. Low Hydraulic Tank Level..........................................................................................1176 B2. Low Automatic Lubrication System Pressure.........................................................................1176 C2. Circuit Breaker Tripped...........................................................................................1176 D2. Hydraulic Oil Filter Monitor......................................................................................1177 E2. Low Fuel..........................................................................................................1177 A3. Parking Brake.....................................................................................................1177 B3. Service Brake.....................................................................................................1177 C3. Body Up...........................................................................................................1177 D3. Dynamic Retarding.................................................................................................1177 E3. Stop Engine.......................................................................................................1178 A4. Cranking Motor Failure............................................................................................1178 B4. Backup Lights.....................................................................................................1178 C4. Engine Shutdown Timer.............................................................................................1178 D4. Retard Speed Control (RSC) Indicator..............................................................................1178 E4. Check Engine......................................................................................................1178 A5. No Power..........................................................................................................1179 B5. Propulsion System Warning.........................................................................................1179 C5. Propulsion System Temperature.....................................................................................1179 D5. System/Component Failure..........................................................................................1179 E5. Battery Charging System Failure...................................................................................1179 A6. No Propel.........................................................................................................1179 B6. Propel System At Rest.............................................................................................1179 C6. Propel System Not Ready...........................................................................................1180 D6. Reduced Propulsion................................................................................................1180 E6. Retard At Continuous Level........................................................................................1180 D7. Brake Test Light..................................................................................................1180 E7. Maintenance Monitor...............................................................................................1180 8. Brake Test Switch..................................................................................................1180 REAR AXLE LIGHT BAR.......................................................................................................1181 Backup Lights.........................................................................................................1181 Retard Lights.........................................................................................................1181 Brake Lights..........................................................................................................1181 Backup Alarm..........................................................................................................1181 KOMTRAX PLUS..............................................................................................................1182 Operation.............................................................................................................1182 Interface Module......................................................................................................1184 Basic Precautions.....................................................................................................1184 KOMATSU WIRELESS BRIDGE (Optional)........................................................................................1185 General Information...................................................................................................1185 Communication Setup...................................................................................................1185 Switching to the KWB_SETUP Network....................................................................................1185 Setting the Computer Subnet Mask and IP Address.......................................................................1186 Properties............................................................................................................1186 Setting Up the KWB....................................................................................................1187 Adding Encryption.....................................................................................................1187 Final Computer Settings...............................................................................................1187 Data Downloading......................................................................................................1188 Resetting the KWB.....................................................................................................1188 KWB Lights............................................................................................................1188 SECTION P LUBRICATION AND SERVICE.....................................................................................................1189 SECTION P2 LUBRICATION AND SERVICE................................................................................................1191 LUBRICATION AND SERVICE.......................................................................................................1193 GENERAL...................................................................................................................1193 SERVICE CAPACITIES........................................................................................................1193 HYDRAULIC TANK SERVICE....................................................................................................1193 Adding Oil............................................................................................................1193 COOLING SYSTEM SERVICE....................................................................................................1194 Radiator Filling Procedure............................................................................................1194 Coolant Specifications................................................................................................1194 Unacceptable Practices................................................................................................1194 WHEEL MOTOR SERVICE.......................................................................................................1194 RESERVE OIL TANK SERVICE..................................................................................................1195 Filling the Reserve Oil Tank (Remote Fill)............................................................................1195 Inline Screen.........................................................................................................1195 QUICK FILL SERVICE CENTER.................................................................................................1196 LUBRICATION CHART.........................................................................................................1197 10 HOUR (DAILY) INSPECTIONS...............................................................................................1198 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................1201 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1201 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1201 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1204 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................1206 5000 HOUR MAINTENANCE CHECKS..............................................................................................1206 SECTION P3 AUTOMATIC LUBRICATION SYSTEM...........................................................................................1207 AUTOMATIC LUBRICATION SYSTEM..................................................................................................1209 GENERAL DESCRIPTION.......................................................................................................1209 SYSTEM COMPONENTS.........................................................................................................1211 Filter................................................................................................................1211 Hydraulic Motor and Pump..............................................................................................1211 Grease Reservoir......................................................................................................1211 Pressure Reducing Valve...............................................................................................1211 Flow Control Valve....................................................................................................1211 Solenoid Valve........................................................................................................1211 Vent Valve............................................................................................................1211 Lubrication Cycle Timer...............................................................................................1211 Over Pressure Cut Off Switch..........................................................................................1211 Grease Pressure Failure Switch........................................................................................1211 Injectors.............................................................................................................1211 Relief Valve (unloader valve).........................................................................................1211 SYSTEM OPERATION..........................................................................................................1212 Normal Operation......................................................................................................1212 Lubricant Required For System.........................................................................................1213 System Priming........................................................................................................1213 Filter Assembly.......................................................................................................1213 LUBRICANT PUMP............................................................................................................1214 Pump Housing Oil Level................................................................................................1214 Pump Pressure Control.................................................................................................1214 INJECTORS (SL-1 Series “H”)...............................................................................................1215 Injector Specifications...............................................................................................1215 Injector Adjustment...................................................................................................1215 INJECTOR OPERATION....................................................................................................1216 PREVENTIVE MAINTENANCE PROCEDURES.........................................................................................1217 Daily Lubrication System Inspection...................................................................................1217 250 Hour Inspection...................................................................................................1217 1000 Hour Inspection..................................................................................................1217 SYSTEM CHECKOUT...........................................................................................................1218 Lubrication Controller Check..........................................................................................1218 Lubrication Controller Components.....................................................................................1218 Lubrication Controller Adjustment.....................................................................................1218 SYSTEM TROUBLESHOOTING CHART..................................................................................................1220 SECTION Q ALPHABETICAL INDEX..........................................................................................................1223 SECTION R SYSTEM SCHEMATICS...........................................................................................................1227 HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC.......................................................................1229 HYDRAULIC BRAKE SYSTEM SCHEMATIC..................................................................................................1230 ELECTRICAL SCHEMATICS.............................................................................................................1231
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