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KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL SN:A30750-A30795 TIER 2 – PDF DOWNLOAD
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- KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30750-A30795 TIER 2
- PUBLICATION NUMBER:CEBM021804
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Description
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL SN:A30750-A30795 TIER 2
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL SN:A30750-A30795 TIER 2 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL SN:A30750-A30795 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:A30750-A30795 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 ENGINE START-UP............................................................................................................... 47 AFTER ENGINE HAS STARTED...................................................................................................... 48 PRE-SHIFT BRAKE CHECK (if equipped)........................................................................................... 48 Events.................................................................................................................... 48 OPERATION..................................................................................................................... 49 Description............................................................................................................... 49 Brake Test Exit Criteria.................................................................................................. 49 PERFORMING THE BRAKE TESTS.................................................................................................... 50 Setup..................................................................................................................... 50 Service Brake Test........................................................................................................ 50 Parking Brake Test........................................................................................................ 51 Retard System Test........................................................................................................ 52 EMERGENCY STEERING SYSTEM..................................................................................................... 52 Operation................................................................................................................. 52 Pre-Operation Testing..................................................................................................... 52 MACHINE OPERATION SAFETY PRECAUTIONS.......................................................................................... 53 OPERATING ON THE HAUL ROAD.................................................................................................... 54 STARTING ON A GRADE WITH A LOADED TRUCK....................................................................................... 55 PASSING....................................................................................................................... 55 LOADING....................................................................................................................... 55 Overload Speed Limit Function............................................................................................. 55 DUMPING....................................................................................................................... 56 Raising The Dump Body..................................................................................................... 56 Lowering The Dump Body (When dumping on flat ground):..................................................................... 57 Lowering The Dump Body (When dumping over a berm or into a crusher):...................................................... 57 TOWING........................................................................................................................ 58 Special Wiring Harness.................................................................................................... 58 SAFE PARKING PROCEDURES....................................................................................................... 60 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................................................................. 60 SUDDEN LOSS OF ENGINE POWER................................................................................................... 61 FUEL DEPLETION................................................................................................................ 61 DISABLED TRUCK DUMPING PROCEDURE.............................................................................................. 62 Hookup.................................................................................................................... 62 Raising the Body.......................................................................................................... 62 Lowering the Body......................................................................................................... 62 WARNINGS AND CAUTIONS............................................................................................................. 63 GRADE/SPEED CHART............................................................................................................. 63 KEY SWITCH.................................................................................................................... 63 ROPS/FOPS..................................................................................................................... 63 BATTERIES..................................................................................................................... 64 CAPACITORS.................................................................................................................... 64 CRUSHING HAZARD............................................................................................................... 65 CYLINDER PRESSURE............................................................................................................. 65 FILLING THE HYDRAULIC TANK.................................................................................................... 66 HYDRAULIC OIL PRESSURE........................................................................................................ 66 HOT OIL SPRAY................................................................................................................. 67 WHEEL MOTOR OIL LEVEL......................................................................................................... 67 HOT EXHAUST................................................................................................................... 67 RADIATOR...................................................................................................................... 67 EMERGENCY LADDER.............................................................................................................. 67 ACCUMULATOR DRAIN VALVES...................................................................................................... 67 EMERGENCY DUMP PROCEDURE...................................................................................................... 68 EMERGENCY TOWING PROCEDURE.................................................................................................... 68 WELDING....................................................................................................................... 68 EMERGENCY SHUTDOWN............................................................................................................ 68 INFORMATION DISPLAY........................................................................................................... 69 WIRELESS SIGNALS.............................................................................................................. 69 HIGH VOLTAGE.................................................................................................................. 69 LIFTING INSTRUCTIONS.......................................................................................................... 70 PRODUCT IDENTIFICATION PLATE.................................................................................................. 71 LUBRICATION CHART............................................................................................................. 72 TORQUE TABLES AND CONVERSION CHARTS............................................................................................... 73 STORAGE AND IDLE MACHINE PREPARATION.............................................................................................. 83 SHORT TERM IDLE PERIODS....................................................................................................... 83 PREPARATION FOR STORAGE....................................................................................................... 84 REMOVAL FROM STORAGE.......................................................................................................... 85 RECONDITIONING AN IDLE VEHICLE................................................................................................ 87 ENGINE OPERATION.............................................................................................................. 89 After The Engine Has Started.............................................................................................. 90 ENGINE STORAGE................................................................................................................ 91 Temporary Storage (30 Days Or Less)....................................................................................... 91 Extended Storage (More Than 30 Days)...................................................................................... 91 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................................................................... 93 ELECTRIC DRIVE TRUCKS......................................................................................................... 94 Storing A Truck That Is Operational....................................................................................... 94 Storing A Truck That Is Not Operational................................................................................... 95 Storing A Major Component................................................................................................. 96 Periodic Inspections...................................................................................................... 96 Placing Equipment Into Service After Storage.............................................................................. 96 SECTION B STRUCTURES.................................................................................................................. 99 SECTION B2 STRUCTURAL COMPONENTS.................................................................................................. 101 STRUCTURAL COMPONENTS......................................................................................................... 103 PREPARATION............................................................................................................... 103 DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY................................................................................. 104 Removal............................................................................................................... 104 Installation.......................................................................................................... 104 RH DECK AND RETARDING GRID................................................................................................ 105 Removal............................................................................................................... 105 Installation.......................................................................................................... 105 LH DECK................................................................................................................... 106 Removal............................................................................................................... 106 Installation.......................................................................................................... 106 CENTER DECK............................................................................................................... 107 Removal............................................................................................................... 107 Installation.......................................................................................................... 107 SECTION B3 DUMP BODY.............................................................................................................. 109 DUMP BODY..................................................................................................................... 111 DUMP BODY................................................................................................................. 111 Removal............................................................................................................... 111 Installation.......................................................................................................... 112 BODY PADS................................................................................................................. 114 Body Pad Shimming Procedure........................................................................................... 115 BODY GUIDE................................................................................................................ 116 HOIST LIMIT SWITCH........................................................................................................ 116 BODY-UP SWITCH............................................................................................................ 116 BODY RETENTION SLING...................................................................................................... 116 ROCK EJECTORS............................................................................................................. 117 Inspection............................................................................................................ 117 SECTION B4 FUEL TANK.............................................................................................................. 119 FUEL TANK..................................................................................................................... 121 FUEL TANK................................................................................................................. 121 Removal............................................................................................................... 121 Repair................................................................................................................ 121 Cleaning.............................................................................................................. 121 Installation.......................................................................................................... 121 FUEL TANK VENT ASSEMBLY................................................................................................... 123 Disassembly........................................................................................................... 123 Assembly.............................................................................................................. 123 FUEL GAUGE SENDER......................................................................................................... 124 Removal............................................................................................................... 124 Installation.......................................................................................................... 124 QUICK FILL FUEL RECEIVERS................................................................................................. 124 SECTION C ENGINE...................................................................................................................... 125 SECTION C2 POWER MODULE........................................................................................................... 127 POWER MODULE.................................................................................................................. 129 PREPARATION FOR REMOVAL................................................................................................... 129 REMOVAL................................................................................................................... 134 INSTALLATION.............................................................................................................. 136 HOOKUP.................................................................................................................... 137 SECTION C3 COOLING SYSTEM......................................................................................................... 139 COOLING SYSTEM................................................................................................................ 141 RADIATOR.................................................................................................................. 141 Removal............................................................................................................... 141 Installation.......................................................................................................... 143 Filling Procedure..................................................................................................... 144 REPAIRING THE RADIATOR.................................................................................................... 144 Internal Inspection................................................................................................... 144 External Cleaning..................................................................................................... 144 Disassembly........................................................................................................... 145 Cleaning and Inspection............................................................................................... 146 Assembly.............................................................................................................. 146 Pressure Testing...................................................................................................... 147 COOLANT SYSTEM TROUBLESHOOTING............................................................................................ 147 SECTION C4 POWER TRAIN............................................................................................................ 149 POWER TRAIN................................................................................................................... 151 ALTERNATOR REMOVAL........................................................................................................ 151 ALTERNATOR INSTALLATION................................................................................................... 153 Measuring Procedure................................................................................................... 153 Joining the Alternator and Engine..................................................................................... 155 ENGINE.................................................................................................................... 156 Removal............................................................................................................... 156 Service............................................................................................................... 156 Installation.......................................................................................................... 156 SECTION C5 AIR CLEANERS........................................................................................................... 157 AIR CLEANERS.................................................................................................................. 159 OPERATION................................................................................................................. 159 SERVICING THE AIR CLEANERS................................................................................................ 159 Replacing The Filter Element.......................................................................................... 159 Cleaning The Main Filter Element...................................................................................... 161 Servicing The Precleaner Section...................................................................................... 162 EVACUATOR VALVES (if equipped)............................................................................................ 163 AIR INTAKE TROUBLESHOOTING................................................................................................ 163 SECTION C7 FAN CLUTCH............................................................................................................. 165 FAN CLUTCH.................................................................................................................... 167 REMOVAL & INSTALLATION TOOLING............................................................................................ 167 DISASSEMBLY............................................................................................................... 170 CLEANING AND INSPECTION................................................................................................... 180 ASSEMBLY.................................................................................................................. 184 TEST PROCEDURE............................................................................................................ 198 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION).................................................................................... 199 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM........................................................................................... 201 24VDC ELECTRIC SUPPLY SYSTEM.................................................................................................. 203 ELECTRICAL SYSTEM DESCRIPTION............................................................................................. 203 BATTERIES................................................................................................................. 203 Maintenance and Service............................................................................................... 203 Troubleshooting....................................................................................................... 203 BATTERY SUPPLY SYSTEM..................................................................................................... 205 24VDC Battery Charging Alternator..................................................................................... 205 Batteries............................................................................................................. 205 24VDC Auxiliary Battery Receptacles................................................................................... 205 Battery Disconnect Switches........................................................................................... 206 Isolation Diode (if equipped)......................................................................................... 206 Engine Start Relay.................................................................................................... 206 24VDC to 12VDC Converter.............................................................................................. 206 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)....................................................................... 207 Operation............................................................................................................. 207 Pressure Switch....................................................................................................... 207 Check Valve........................................................................................................... 207 Timer Solenoid........................................................................................................ 207 MAINTENANCE............................................................................................................... 208 Prelube System Operation Checks....................................................................................... 208 Check Valve........................................................................................................... 208 Timer Solenoid........................................................................................................ 208 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT................................................................................ 209 24VDC ELECTRIC START SYSTEM................................................................................................... 211 CRANKING MOTORS........................................................................................................... 211 Operation............................................................................................................. 211 Removal............................................................................................................... 211 Installation.......................................................................................................... 211 CRANKING MOTOR TROUBLESHOOTING............................................................................................ 212 Preliminary Inspection................................................................................................ 212 No-Load Test.......................................................................................................... 212 Interpreting Results of Tests......................................................................................... 213 Disassembly........................................................................................................... 213 Cleaning and Inspection............................................................................................... 214 Armature Servicing.................................................................................................... 216 Field Coil Checks..................................................................................................... 216 Field Coil Removal.................................................................................................... 216 SOLENOID CHECKS........................................................................................................... 217 Test.................................................................................................................. 217 Assembly.............................................................................................................. 218 Bearing Replacement:.................................................................................................. 218 Motor Assembly:....................................................................................................... 218 Pinion Clearance...................................................................................................... 219 MAGNETIC SWITCH........................................................................................................... 219 Removal............................................................................................................... 219 Installation.......................................................................................................... 219 Coil Test............................................................................................................. 220 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS..................................................................................... 221 24 VDC ELECTRICAL SYSTEM COMPONENTS........................................................................................... 223 BRAKE WARNING BUZZER...................................................................................................... 223 AUXILIARY CONTROL CABINET COMPONENTS...................................................................................... 223 Power Distribution Terminals.......................................................................................... 223 Control Power Relay................................................................................................... 223 Auto Lube Timer....................................................................................................... 223 Ground Level Power Relay.............................................................................................. 223 Diode Board - DB1..................................................................................................... 225 Fuse Blocks........................................................................................................... 226 Alarm Indicating Device (AID) System.................................................................................. 226 RELAY BOARDS.............................................................................................................. 229 Relay Boards RB1, RB3, RB4, RB5....................................................................................... 229 Relay Board RB6, RB7, RB8, RB9........................................................................................ 231 Relay Board Functions................................................................................................. 232 BODY-UP SWITCH............................................................................................................ 234 Operation............................................................................................................. 234 Adjustment............................................................................................................ 234 Service............................................................................................................... 234 HOIST LIMIT SWITCH........................................................................................................ 236 Operation............................................................................................................. 236 Adjustment............................................................................................................ 236 Service............................................................................................................... 236 FUSE BLOCKS AND CIRCUIT BREAKERS.......................................................................................... 238 SECTION D11 KOMTRAX PLUS.......................................................................................................... 241 KOMTRAX PLUS.................................................................................................................. 243 KOMTRAX PLUS BASIC FEATURES............................................................................................... 243 Gather Data........................................................................................................... 243 Convert and Record Data............................................................................................... 243 Communicate Data to Off-Board Systems................................................................................. 244 USING KOMTRAX PLUS........................................................................................................ 245 Turning KOMTRAX Plus ON............................................................................................... 245 Normal KOMTRAX Plus Operation......................................................................................... 245 Turning KOMTRAX Plus OFF.............................................................................................. 246 Downloading from the KOMTRAX Plus Controller.......................................................................... 246 KOMTRAX PLUS DATA ITEMS................................................................................................... 247 Fault Codes........................................................................................................... 247 Machine History....................................................................................................... 247 KOMTRAX Plus History.................................................................................................. 247 Snapshots............................................................................................................. 248 Manual Snapshots...................................................................................................... 248 Trends................................................................................................................ 250 Histogram (Load Map) Data............................................................................................. 250 Haul Cycle Data....................................................................................................... 251 Alarm and Snapshot Triggers........................................................................................... 252 Satellite Features.................................................................................................... 252 KOMTRAX PLUS DIAGNOSTIC FEATURES.......................................................................................... 254 Fault History......................................................................................................... 254 LED Digits............................................................................................................ 254 KOMTRAX PLUS CONTROLLER................................................................................................... 254 Removal............................................................................................................... 255 Installation.......................................................................................................... 255 KOMTRAX PLUS SOFTWARE..................................................................................................... 256 VHMS Tool Box Installation............................................................................................ 256 VHMS Setting Tool Installation........................................................................................ 256 PDM Software Installation............................................................................................. 256 KOMTRAX PLUS INITIALIZATION PROCEDURE..................................................................................... 257 CONTROLLER SETUP PROCEDURE............................................................................................ 257 SNAPSHOT PROCEDURE.................................................................................................... 260 DOWNLOAD PROCEDURE.................................................................................................... 261 FTP UPLOAD PROCEDURE.................................................................................................. 262 INITIALIZATION FORMS.................................................................................................. 263 WHEN REPLACING A KOMTRAX PLUS CONTROLLER.................................................................................. 264 KOMTRAX PLUS CONTROLLER CHECKOUT.......................................................................................... 269 Necessary Equipment................................................................................................... 269 Preliminary........................................................................................................... 269 KOMTRAX Plus Controller Checkout Procedure............................................................................ 270 ORBCOMM CONTROLLER (if equipped).......................................................................................... 272 Removal............................................................................................................... 272 Installation.......................................................................................................... 272 SECTION D12 INTERFACE MODULE...................................................................................................... 273 INTERFACE MODULE.............................................................................................................. 275 Removal................................................................................................................... 275 Installation.............................................................................................................. 275 SENSORS....................................................................................................................... 276 Temperature Sensors....................................................................................................... 276 Pressure Sensors.......................................................................................................... 276 INTERFACE MODULE SOFTWARE..................................................................................................... 277 Flashburn Program Installation............................................................................................ 277 Interface Module Application Code Installation............................................................................ 278 Interface Module Realtime Data Monitor Software........................................................................... 278 INTERFACE MODULE CHECKOUT..................................................................................................... 279 Necessary Equipment....................................................................................................... 279 Preliminary............................................................................................................... 280 Check Digital Inputs To The Interface Module.............................................................................. 281 Check Analog Inputs To The Interface Module............................................................................... 284 Check Serial Interfaces To The Interface Module........................................................................... 284 Check Outputs From The Interface Module................................................................................... 285 SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING..................................................................... 287 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING............................................................................. 289 GENERAL................................................................................................................... 289 TROUBLESHOOTING........................................................................................................... 290 Communications Networks............................................................................................... 290 Coaxial Cable......................................................................................................... 290 FAULT CODES............................................................................................................... 290 Fault History......................................................................................................... 290 KOMTRAX Plus LED Display Fault Codes.................................................................................. 291 Chassis Fault Codes................................................................................................... 292 Engine Fault Codes.................................................................................................... 296 FAULT TREE ANALYSIS....................................................................................................... 302 Unable to connect to KOMTRAX Plus from laptop PC...................................................................... 302 Flashing Error Code N4-23 (PLM III Communications Fault).............................................................. 303 Flashing Error Code N4-22 (Engine Communications Fault)............................................................... 304 No Data Received By WebCARE........................................................................................... 305 Coaxial Cable Troubleshooting......................................................................................... 306 SECTION D14 KOMTRAX PLUS FORMS.................................................................................................... 307 KOMTRAX PLUS FORMS............................................................................................................ 309 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 309 KOMTRAX PLUS DATA DOWNLOAD................................................................................................ 310 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 311 KOMTRAX PLUS INITIALIZATION FORM.......................................................................................... 313 SECTION E ELECTRIC PROPULSION SYSTEM.................................................................................................. 315 SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS.................................................................................. 317 ELECTRICAL PROPULSION SYSTEM COMPONENTS....................................................................................... 319 GENERAL SYSTEM DESCRIPTION................................................................................................ 319 SYSTEM COMPONENTS......................................................................................................... 321 Propulsion System Controller (PSC).................................................................................... 321 Truck Control Interface (TCI)......................................................................................... 322 Diagnostic Information Display (DID) Panel............................................................................ 323 DID Panel Event Codes................................................................................................. 323 PSC SOFTWARE FUNCTIONS.................................................................................................... 342 Input Processing...................................................................................................... 342 State Machine......................................................................................................... 342 DC Link State......................................................................................................... 345 Engine Control........................................................................................................ 346 ALTERNATOR FIELD CONTROL.................................................................................................. 346 Desired Three-Phase Voltage........................................................................................... 346 Desired DC Link Voltage............................................................................................... 346 Self-Load............................................................................................................. 347 Propel Torque Control................................................................................................. 347 Retard Torque Control................................................................................................. 347 Wheel Slide Control................................................................................................... 348 Resistor Grid Control................................................................................................. 348 Chopper Voltage Control............................................................................................... 348 EVENT DETECTION AND PROCESSING............................................................................................ 348 Power-On Tests........................................................................................................ 348 Initiated Tests....................................................................................................... 349 Periodic Tests........................................................................................................ 349 EVENT RESTRICTIONS........................................................................................................ 349 EVENT LOGGING AND STORAGE................................................................................................. 349 Event History Buffer.................................................................................................. 350 Data Packs............................................................................................................ 350 To Record and Save a Data Pack to a Disk.............................................................................. 350 Event Reset........................................................................................................... 351 SERIAL DATA COMMUNICATIONS................................................................................................ 351 PSC - TCI Communications Processing................................................................................... 351 PSC - PTU Communications Processing................................................................................... 351 Inverter Communications Processing.................................................................................... 352 OUTPUT PROCESSING......................................................................................................... 352 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS.................................................................................. 352 Fast Start............................................................................................................ 352 Engine Shutdown/Engine Not Running.................................................................................... 352 Limp Home Mode........................................................................................................ 353 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS..................................................................... 354 ELECTRONIC ACCELERATOR AND RETARD PEDALS.................................................................................. 362 Removal............................................................................................................... 362 Installation.......................................................................................................... 362 Disassembly........................................................................................................... 362 Assembly.............................................................................................................. 362 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.......................................................................... 363 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE................................................................................. 365 AC DRIVE SYSTEM MAINTENANCE............................................................................................... 365 NORMAL TRUCK SHUTDOWN PROCEDURE........................................................................................... 366 SHUTDOWN AFTER SYSTEM FAILURE............................................................................................. 366 SYSTEM CHECKOUT........................................................................................................... 367 Battery and Control Circuit Checks - Battery Power OFF................................................................ 367 Battery and Control Circuit Checks - Battery Power ON................................................................. 370 Checks with Key Switch OFF............................................................................................ 371 Checks with Key Switch ON............................................................................................. 371 CPU Battery Checks.................................................................................................... 371 MEMORY BACKUP BATTERY REPLACEMENT......................................................................................... 372 TCI PROGRAMMING........................................................................................................... 372 PSC PROGRAMMING........................................................................................................... 373 INVERTER PROGRAMMING...................................................................................................... 373 CPU RESET................................................................................................................. 373 PSC CHECKOUT.............................................................................................................. 374 PSC Digital Input Checks.............................................................................................. 374 PSC Digital Output Checks............................................................................................. 378 TCI CHECKOUT.............................................................................................................. 379 Modular Mining Communication Port Check............................................................................... 379 TCI Digital Input Checks.............................................................................................. 379 TCI Digital Output Tests.............................................................................................. 385 CALIBRATIONS.............................................................................................................. 387 Speedometer........................................................................................................... 387 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial.................................................................. 387 ERASING EVENTS............................................................................................................ 387 PSC................................................................................................................... 387 TCI................................................................................................................... 388 GATE DRIVER POWER CONVERTER TEST.......................................................................................... 388 LOAD TESTING.............................................................................................................. 389 Preparation........................................................................................................... 389 Alternator Speed Sensor Checks........................................................................................ 389 Battery Boost Check................................................................................................... 389 Brake Circuit Switch Checks........................................................................................... 390 Hoist & Steering Circuit Switch Checks................................................................................ 390 Link Energized Checks................................................................................................. 390 Loadbox Test.......................................................................................................... 392 TROUBLESHOOTING........................................................................................................... 396 PVM Optimum Load Curve Handshaking Troubleshooting.................................................................... 396 Phase Module and Chopper Module Troubleshooting....................................................................... 396 PHASE MODULE REPLACEMENT.................................................................................................. 397 Phase Module Removal.................................................................................................. 397 Phase Module Installation............................................................................................. 397 SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146)................................................................................ 399 Fault Code A001: Left front suspension pressure sensor signal is high......................................................... 401 Related circuit diagram................................................................................................... 401 Fault Code A002: Left front suspension pressure sensor signal is low.......................................................... 402 Related circuit diagram................................................................................................... 402 Fault Code A003: Right front suspension pressure sensor signal is high........................................................ 403 Related circuit diagram................................................................................................... 403 Fault Code A004: Right front suspension pressure sensor signal is low......................................................... 404 Related circuit diagram................................................................................................... 404 Fault Code A005: Left rear suspension pressure sensor signal is high.......................................................... 405 Related circuit diagram................................................................................................... 405 Fault Code A006: Left rear suspension pressure sensor signal is low........................................................... 406 Related circuit diagram................................................................................................... 406 Fault Code A007: Right rear suspension pressure sensor signal is high......................................................... 407 Related circuit diagram................................................................................................... 407 Fault Code A008: Right rear suspension pressure sensor signal is low.......................................................... 408 Related circuit diagram................................................................................................... 408 Fault Code A009: Incline sensor signal is high................................................................................ 409 Related circuit diagram................................................................................................... 409 Fault Code A010: Incline sensor signal is low................................................................................. 410 Related circuit diagram................................................................................................... 410 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 411 Related circuit diagram................................................................................................... 411 Fault Code A013: Body up switch has failed.................................................................................... 412 Related circuit diagram................................................................................................... 412 Fault Code A014: Payload meter checksum computation has failed................................................................ 413 Related circuit diagram................................................................................................... 413 Fault Code A016: Payload meter write to flash memory has failed............................................................... 414 Related circuit diagram................................................................................................... 414 Fault Code A017: Payload meter flash memory read has failed................................................................... 415 Related circuit diagram................................................................................................... 415 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 416 Related circuit diagram................................................................................................... 417 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 418 Related circuit diagram................................................................................................... 419 Fault Code A022: Carryback load is excessive.................................................................................. 420 Related circuit diagram................................................................................................... 421 Fault Code A026: Payload meter user select switch has failed.................................................................. 422 Related circuit diagram................................................................................................... 422 Fault Code A027: Payload meter user clear switch has failed................................................................... 423 Related circuit diagram................................................................................................... 423 Fault Code A101: High pressure detected across a hydraulic pump filter........................................................ 424 Related circuit diagram................................................................................................... 425 Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level................................... 426 Related circuit diagram................................................................................................... 427 Fault Code A107: GE has generated a propel system caution..................................................................... 428 Related circuit diagram................................................................................................... 429 Fault Code A108: GE has generated a propel system temperature caution......................................................... 430 Related circuit diagram................................................................................................... 431 Fault Code A109: GE has generated a propel system reduced level signal........................................................ 432 Related circuit diagram................................................................................................... 433 Fault Code A115: Low steering precharge pressure is detected.................................................................. 434 Related circuit diagram................................................................................................... 435 Fault Code A123: GE has generated a reduced retarding caution................................................................. 436 Related circuit diagram................................................................................................... 437 Fault Code A124: GE has generated a no propel / no retard warning............................................................. 438 Related circuit diagram................................................................................................... 439 Fault Code A125: GE has generated a no propel warning......................................................................... 440 Related circuit diagram................................................................................................... 441 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 442 Related circuit diagram................................................................................................... 443 Fault Code A127: IM furnished +5 volt output for sensors is low............................................................... 444 Related circuit diagram................................................................................................... 445 Fault Code A128: IM furnished +5 volt output for sensors is high.............................................................. 446 Related circuit diagram................................................................................................... 447 Fault Code A139, A310: Low fuel level warning................................................................................. 448 Related circuit diagram................................................................................................... 449 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 450 Related circuit diagram................................................................................................... 451 Fault Code A146: Hydraulic temperature sensors cause posting of this faultl................................................... 452 Related circuit diagram................................................................................................... 453 SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216)................................................................................ 455 Fault Code A152: Starter failure.............................................................................................. 456 Related circuit diagram................................................................................................... 457 Fault Code A153: Battery voltage is low with truck in operation............................................................... 458 Related circuit diagram................................................................................................... 459 Fault Code A154: Battery charging voltage is excessive........................................................................ 460 Related circuit diagram................................................................................................... 461 Fault Code A155: Battery charging voltage is low.............................................................................. 462 Related circuit diagram................................................................................................... 463 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 464 Related circuit diagram................................................................................................... 465 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 466 Related circuit diagram................................................................................................... 467 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 468 Related circuit diagram................................................................................................... 469 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 470 Related circuit diagram................................................................................................... 471 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 472 Related circuit diagram................................................................................................... 473 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 474 Related circuit diagram................................................................................................... 474 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 475 Related circuit diagram................................................................................................... 475 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 476 Related circuit diagram................................................................................................... 476 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 477 Related circuit diagram................................................................................................... 477 Fault Code A184: J1939 data link is not connected............................................................................. 478 Related circuit diagram................................................................................................... 479 Fault Code A190: Auto lube control has detected an incomplete lube cycle...................................................... 480 Related circuit diagram................................................................................................... 481 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 482 Related circuit diagram................................................................................................... 483 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 484 Related circuit diagram....................................................................................................... 485 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 486 Related circuit diagram....................................................................................................... 487 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 488 Related circuit diagram....................................................................................................... 489 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 490 Related circuit diagram................................................................................................... 490 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 491 Related circuit diagram................................................................................................... 491 Fault Code A200: Steering pressure sensor is high............................................................................. 492 Related circuit diagram................................................................................................... 492 Fault Code A201: Brake pressure sensor is high................................................................................ 493 Related circuit diagram................................................................................................... 493 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 494 Related circuit diagram................................................................................................... 494 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 495 Related circuit diagram................................................................................................... 495 Fault Code A204: Steering pressure sensor is low.............................................................................. 496 Related circuit diagram................................................................................................... 496 Fault Code A205: Brake pressure sensor is low................................................................................. 497 Related circuit diagram................................................................................................... 497 Fault Code A206: Ambient temperature sensor is high........................................................................... 498 Related circuit diagram................................................................................................... 498 Fault Code A207: Ambient temperature sensor is low............................................................................ 499 Related circuit diagram................................................................................................... 499 Fault Code A212: Bad truck speed signal....................................................................................... 500 Related circuit diagram................................................................................................... 501 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 502 Related circuit diagram................................................................................................... 504 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 506 Related circuit diagram................................................................................................... 508 Fault Code A215: Brake auto apply relay circuit is defective.................................................................. 510 Related circuit diagram................................................................................................... 511 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 512 Related circuit diagram................................................................................................... 513 SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292)................................................................................ 515 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 516 Related circuit diagram................................................................................................... 517 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 518 Related circuit diagram................................................................................................... 519 Fault Code A236: Steering accumulator has not properly bled down after 90 seconds............................................. 520 Related circuit diagram................................................................................................... 521 Fault Code A240: The keyswitch input to the interface module is open.......................................................... 522 Related circuit diagram................................................................................................... 523 Fault Code A246: Payload meter reports truck overload......................................................................... 523 Related circuit diagram................................................................................................... 523 Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted............................... 524 Related circuit diagram................................................................................................... 525 Fault Code A250: Battery voltage is low with the truck parked................................................................. 526 Related circuit diagram................................................................................................... 527 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 528 Related circuit diagram................................................................................................... 529 Fault Code A253: Steering bleed circuit is not open while running............................................................. 530 Related circuit diagram................................................................................................... 531 Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open.................................. 532 Related circuit diagram................................................................................................... 533 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 534 Related circuit diagram................................................................................................... 534 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 536 Related circuit diagram................................................................................................... 537 Fault Code A260: Parking brake failure........................................................................................ 538 Related circuit diagram................................................................................................... 539 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 540 Related circuit diagram................................................................................................... 541 Fault Code A263: Steering bleed circuit is shorted to ground.................................................................. 542 Related circuit diagram................................................................................................... 543 Fault Code A264: Parking brake relay circuit is defective..................................................................... 544 Related circuit diagram................................................................................................... 545 Fault Code A265: Service brake failure........................................................................................ 546 Related circuit diagram................................................................................................... 548 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 550 Related circuit diagram................................................................................................... 551 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 552 Related circuit diagram................................................................................................... 554 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 556 Related circuit diagram................................................................................................... 557 Fault Code A274: A brake setting fault has been detected...................................................................... 558 Related circuit diagram................................................................................................... 559 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 560 Related circuit diagram................................................................................................... 561 Fault Code A276: The drive system data link is not connected.................................................................. 562 Related circuit diagram................................................................................................... 563 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 564 Related circuit diagram................................................................................................... 565 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................... 566 Related circuit diagram................................................................................................... 567 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated...................... 568 Related circuit diagram................................................................................................... 569 Fault Code A285: The parking brake was not set when the key switch was turned off............................................. 570 Related circuit diagram................................................................................................... 571 Fault Code A286: A fault was detected in the shutdown delay relay circuit..................................................... 572 Related circuit diagram................................................................................................... 573 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off......................... 574 Related circuit diagram................................................................................................... 575 SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365)................................................................................ 577 Fault Code A303: Shifter is defective......................................................................................... 578 Related circuit diagram................................................................................................... 579 Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be............ 580 Related circuit diagram................................................................................................... 581 Fault Code A309: No brakes applied when expected.............................................................................. 582 Related circuit diagram................................................................................................... 584 Fault Code A311: Brake lock switch is on when it should not be................................................................ 586 Related circuit diagram................................................................................................... 587 Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings............................................ 588 Related circuit diagram................................................................................................... 588 Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings........................................... 589 Related circuit diagram................................................................................................... 589 Fault Code A315: DC-DC converter 12 volt circuit is low....................................................................... 590 Related circuit diagram................................................................................................... 591 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 592 Related circuit diagram................................................................................................... 593 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 594 Related circuit diagram................................................................................................... 596 Fault Code A318: Unexpected power loss to interface module.................................................................... 597 Related circuit diagram................................................................................................... 597 Fault Code A328: Drive system not powered up.................................................................................. 598 Related circuit diagram................................................................................................... 599 Fault Code A350: Overload on output 1B........................................................................................ 600 Related circuit diagram................................................................................................... 601 Fault Code A351: Overload on output 1E........................................................................................ 602 Related circuit diagram................................................................................................... 603 Fault Code A352: Overload on output 1H........................................................................................ 604 Related circuit diagram................................................................................................... 605 Fault Code A353: Overload on output 1J........................................................................................ 606 Related circuit diagram................................................................................................... 607 Fault Code A354: Overload on output 1K........................................................................................ 608 Related circuit diagram................................................................................................... 609 Fault Code A355: Overload on output 1L........................................................................................ 610 Related circuit diagram................................................................................................... 611 Fault Code A356: Overload on output 1M........................................................................................ 612 Related circuit diagram................................................................................................... 613 Fault Code A357: Overload on output 1N........................................................................................ 614 Related circuit diagram................................................................................................... 615 Fault Code A358: Overload on output 1P........................................................................................ 616 Related circuit diagram................................................................................................... 617 Fault Code A359: Overload on output 1R........................................................................................ 618 Related circuit diagram................................................................................................... 619 Fault Code A360: Overload on output 1S........................................................................................ 620 Related circuit diagram................................................................................................... 621 Fault Code A361: Overload on output 1T........................................................................................ 622 Related circuit diagram................................................................................................... 623 Fault Code A362: Overload on output 1U........................................................................................ 624 Related circuit diagram................................................................................................... 625 Fault Code A363: Overload on output 1X........................................................................................ 626 Related circuit diagram................................................................................................... 626 Fault Code A364: Overload on output 1Y........................................................................................ 628 Related circuit diagram................................................................................................... 629 Fault Code A365: Overload on output 1Z........................................................................................ 630 Related circuit diagram................................................................................................... 631 SECTION G REAR AXLE, SPINDLES AND WHEELS.............................................................................................. 633 SECTION G2 TIRES AND RIMS......................................................................................................... 635 TIRES AND RIMS................................................................................................................ 637 WHEEL STUD MAINTENANCE.................................................................................................... 638 FRONT TIRES AND RIMS...................................................................................................... 639 Removal............................................................................................................... 639 Installation.......................................................................................................... 640 REAR TIRES AND RIMS....................................................................................................... 641 Removal............................................................................................................... 641 Installation.......................................................................................................... 642 RIM....................................................................................................................... 643 Tire Removal.......................................................................................................... 643 Tire Installation..................................................................................................... 643 SECTION G3 FRONT WHEEL HUB AND SPINDLE............................................................................................ 645 FRONT WHEEL HUB AND SPINDLE................................................................................................... 647 WHEEL HUB AND SPINDLE ASSEMBLY............................................................................................ 647 Removal............................................................................................................... 647 Spindle Removal Procedure (off of the truck).......................................................................... 650 Installation.......................................................................................................... 652 Disassembly........................................................................................................... 653 Cleaning and Inspection............................................................................................... 655 Assembly.............................................................................................................. 655 Wheel Bearing Adjustment.............................................................................................. 656 Brake Installation.................................................................................................... 657 Seal Assembly Gap Check............................................................................................... 658 WHEEL SPEED SENSOR TESTING................................................................................................ 659 STEERING CYLINDERS........................................................................................................ 660 Spherical Bearing Wear Limits......................................................................................... 660 Removal............................................................................................................... 661 Installation.......................................................................................................... 661 Bearing Replacement (Steering Cylinder and Tie Rod)................................................................... 661 TIE ROD................................................................................................................... 663 Removal............................................................................................................... 663 Installation.......................................................................................................... 663 Disassembly........................................................................................................... 664 Assembly.............................................................................................................. 664 Toe-In Adjustment..................................................................................................... 665 TIE ROD INSPECTION AND TORQUE PROCEDURE................................................................................... 666 Old Style Tie Rod..................................................................................................... 666 New Style Tie Rod..................................................................................................... 667 SECTION G4 REAR AXLE MOUNTING..................................................................................................... 669 REAR AXLE MOUNTING............................................................................................................ 671 PIVOT PIN................................................................................................................. 671 Removal............................................................................................................... 671 Installation.......................................................................................................... 672 PIVOT EYE BEARING......................................................................................................... 673 Removal............................................................................................................... 673 Installation.......................................................................................................... 673 PIVOT EYE REPAIR.......................................................................................................... 673 Removal............................................................................................................... 673 Disassembly........................................................................................................... 673 Assembly.............................................................................................................. 674 Installation.......................................................................................................... 674 ANTI-SWAY BAR............................................................................................................. 674 Removal............................................................................................................... 674 Disassembly........................................................................................................... 675 Cleaning and Inspection............................................................................................... 675 Assembly.............................................................................................................. 675 Installation.......................................................................................................... 675 SECTION G5 REAR AXLE AND WHEEL MOTOR.............................................................................................. 677 REAR AXLE AND WHEEL MOTOR..................................................................................................... 679 REAR AXLE HOUSING......................................................................................................... 679 Preparation........................................................................................................... 679 Removal............................................................................................................... 680 Cleaning and Inspection............................................................................................... 681 Installation.......................................................................................................... 681 BLOWER PRESSURE SWITCH ADJUSTMENT......................................................................................... 681 WHEEL MOTOR............................................................................................................... 682 Preparation........................................................................................................... 682 Removal............................................................................................................... 683 Cleaning and Inspection............................................................................................... 685 Installation.......................................................................................................... 685 WHEEL MOTOR GEAR OIL...................................................................................................... 690 Filtering Requirements................................................................................................ 690 Particle Size Analysis................................................................................................ 690 Flushing.............................................................................................................. 690 Oil Sample Analysis................................................................................................... 691 ELEMENT SPECIFICATION CHARTS.............................................................................................. 692 SECTION H HYDRAIR® II SUSPENSIONS..................................................................................................... 695 SECTION H2 FRONT SUSPENSIONS...................................................................................................... 697 FRONT SUSPENSION.............................................................................................................. 699 Removal................................................................................................................... 699 Installation.............................................................................................................. 700 Inspection................................................................................................................ 705 LOWER BEARING & SEALS..................................................................................................... 706 Removal............................................................................................................... 706 Installation.......................................................................................................... 706 MAJOR SUSPENSION REBUILD.................................................................................................. 707 Disassembly........................................................................................................... 707 Assembly.............................................................................................................. 708 SUSPENSION PRESSURE TEST.................................................................................................. 709 SECTION H3 REAR SUSPENSIONS....................................................................................................... 711 REAR SUSPENSIONS.............................................................................................................. 713 SUSPENSION CYLINDER....................................................................................................... 714 Removal............................................................................................................... 714 Installation.......................................................................................................... 716 Disassembly........................................................................................................... 716 Cleaning and Inspection............................................................................................... 717 Assembly.............................................................................................................. 717 SUSPENSION PRESSURE TEST.................................................................................................. 719 SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES.............................................................................. 721 SUSPENSION OILING AND CHARGING PROCEDURE...................................................................................... 723 GENERAL................................................................................................................... 723 EQUIPMENT LIST............................................................................................................ 723 HYDRAIR® CHARGING KIT..................................................................................................... 724 Installation of Charging Kit.......................................................................................... 724 Removal of Charging Kit............................................................................................... 724 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS......................................................................... 725 FRONT SUSPENSION.......................................................................................................... 725 Front Suspension Oiling............................................................................................... 725 Front Suspension Nitrogen Charging.................................................................................... 727 REAR SUSPENSION........................................................................................................... 728 Rear Suspension Oiling................................................................................................ 729 Rear Suspension Nitrogen Charging..................................................................................... 731 OIL AND NITROGEN SPECIFICATIONS CHARTS........................................................................................ 732 SECTION J BRAKE CIRCUIT............................................................................................................... 733 SECTION J2 BRAKE CIRCUIT.......................................................................................................... 735 BRAKE CIRCUIT................................................................................................................. 737 SERVICE BRAKE CIRCUIT..................................................................................................... 737 PARKING BRAKE CIRCUIT..................................................................................................... 739 BRAKE LOCK CIRCUIT........................................................................................................ 739 SECONDARY BRAKING AND AUTOMATIC APPLY..................................................................................... 740 WARNING CIRCUIT........................................................................................................... 740 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE........................................................................................ 743 BRAKE CIRCUIT COMPONENT SERVICE............................................................................................... 745 BRAKE VALVE............................................................................................................... 745 Rebuild Criteria...................................................................................................... 745 Removal............................................................................................................... 746 Installation.......................................................................................................... 746 Disassembly........................................................................................................... 747 Cleaning and Inspection............................................................................................... 750 Assembly.............................................................................................................. 750 Regulator Sleeve O-Ring Installation.................................................................................. 751 BRAKE VALVE BENCH TEST AND ADJUSTMENT..................................................................................... 753 Test Setup Procedure.................................................................................................. 754 Brake Valve Output Pressure Adjustment................................................................................ 754 Final Test and Adjustment............................................................................................. 755 Installing Brake Pedal Actuator Assembly to Brake Valve............................................................... 755 Installing Retard Pedal To Brake Pedal................................................................................ 755 DUAL RELAY VALVE.......................................................................................................... 756 Removal............................................................................................................... 756 Installation.......................................................................................................... 756 Disassembly........................................................................................................... 756 Cleaning and Inspection............................................................................................... 757 Assembly.............................................................................................................. 758 DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT................................................................................ 759 Test Setup Procedure.................................................................................................. 760 Relay Valve Output Pressure Adjustment................................................................................ 760 BRAKE MANIFOLD............................................................................................................ 761 Removal............................................................................................................... 761 Installation.......................................................................................................... 761 Disassembly........................................................................................................... 761 Cleaning and Inspection............................................................................................... 762 Assembly.............................................................................................................. 762 BRAKE ACCUMULATORS........................................................................................................ 762 Brake Accumulator Bleeddown Procedure................................................................................. 762 Removal............................................................................................................... 763 Installation.......................................................................................................... 763 Disassembly........................................................................................................... 764 Cleaning and Inspection............................................................................................... 765 Assembly.............................................................................................................. 765 Accumulator Charging Procedure........................................................................................ 767 Precharge Maintenance................................................................................................. 769 Accumulator Storage Procedures........................................................................................ 770 Bladder Storage Procedures............................................................................................ 770 Installing A Bladder Accumulator From Storage......................................................................... 770 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................................................... 771 Removal............................................................................................................... 771 Installation.......................................................................................................... 771 Disassembly........................................................................................................... 771 Lever Adjustments..................................................................................................... 771 Potentiometer Check................................................................................................... 772 Assembly.............................................................................................................. 772 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE...................................................................................... 775 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................................................. 777 REQUIRED EQUIPMENT........................................................................................................ 778 INITIAL SYSTEM SETUP...................................................................................................... 779 BRAKE LOCK / SECONDARY BRAKE CHECK-OUT.................................................................................... 780 PARKING BRAKE CHECK-OUT................................................................................................... 781 SERVICE BRAKE CHECK-OUT................................................................................................... 782 LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT......................................................................... 783 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART........................................................................... 784 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET......................................................................... 786 SECTION J5 WET DISC BRAKE ASSEMBLY................................................................................................ 789 WET DISC BRAKE ASSEMBLY....................................................................................................... 791 OPERATION................................................................................................................. 791 BRAKE DISC WEAR INSPECTION................................................................................................ 792 BRAKE REBUILD............................................................................................................. 793 Disassembly........................................................................................................... 793 Cleaning and Inspection............................................................................................... 797 Assembly.............................................................................................................. 798 Floating Ring Seal Assembly & Installation............................................................................ 803 WET DISC BRAKE BLEEDING PROCEDURE......................................................................................... 807 SECTION J7 PARKING BRAKE.......................................................................................................... 809 PARKING BRAKE................................................................................................................. 811 OPERATION................................................................................................................. 811 MAINTENANCE............................................................................................................... 812 Inspection............................................................................................................ 812 Removal............................................................................................................... 812 Installation.......................................................................................................... 813 Disassembly........................................................................................................... 813 Cleaning and Inspection............................................................................................... 813 Assembly.............................................................................................................. 815 Cleaning and Inspecting New Discs..................................................................................... 816 PARKING BRAKE BLEEDING PROCEDURE.......................................................................................... 817 SECTION L HYDRAULIC SYSTEM............................................................................................................ 819 SECTION L2 HYDRAULIC SYSTEM....................................................................................................... 821 HYDRAULIC SYSTEM.............................................................................................................. 823 HYDRAULIC PUMP MODULE..................................................................................................... 823 HOIST CIRCUIT OPERATION................................................................................................... 824 STEERING CIRCUIT OPERATION................................................................................................ 826 DISC BRAKE COOLING SYSTEM................................................................................................. 828 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR...................................................................................... 831 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................................................. 833 HOIST PUMP................................................................................................................ 833 Removal............................................................................................................... 833 Installation.......................................................................................................... 835 Inspection............................................................................................................ 840 Assembly.............................................................................................................. 840 HYDRAULIC TANK............................................................................................................ 846 Removal............................................................................................................... 846 Installation.......................................................................................................... 847 HYDRAULIC TANK BREATHERS.................................................................................................. 847 HYDRAULIC TANK STRAINERS.................................................................................................. 848 Removal............................................................................................................... 848 Inspect and Clean..................................................................................................... 848 Installation.......................................................................................................... 848 SECTION L4 STEERING CIRCUIT....................................................................................................... 849 STEERING CIRCUIT.............................................................................................................. 851 STEERING CIRCUIT OPERATION................................................................................................ 851 COMPONENT DESCRIPTION..................................................................................................... 852 Steering Control Unit................................................................................................. 852 Bleeddown Manifold.................................................................................................... 853 Steering Accumulator Bleed Down Solenoid.............................................................................. 853 Relief Valves......................................................................................................... 855 Hoist Up Limit Solenoid............................................................................................... 855 Steering Accumulators................................................................................................. 855 Low Precharge Warning Switch.......................................................................................... 855 High Pressure Filter.................................................................................................. 855 Quick Disconnect Ports................................................................................................ 855 Flow Amplifier........................................................................................................ 857 FLOW AMPLIFIER SYSTEM OPERATION........................................................................................... 858 No Steer.............................................................................................................. 858 Steering Left......................................................................................................... 860 Steering Right........................................................................................................ 862 No Steer, External Shock Load......................................................................................... 864 STEERING PUMP............................................................................................................. 866 Normal Operation...................................................................................................... 866 PRINCIPLE OF OPERATION.................................................................................................... 868 Full Pump Volume...................................................................................................... 868 Half Pump Volume...................................................................................................... 868 Neutral Position...................................................................................................... 868 Steering Pump......................................................................................................... 869 SECTION L5 STEERING CONTROL UNIT.................................................................................................. 871 STEERING CONTROL UNIT......................................................................................................... 873 REMOVAL................................................................................................................... 873 SPLINE INSPECTION......................................................................................................... 873 INSTALLATION.............................................................................................................. 874 DISASSEMBLY............................................................................................................... 874 CLEANING AND INSPECTION................................................................................................... 875 ASSEMBLY.................................................................................................................. 877 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR...................................................................................... 881 STEERING CIRCUIT COMPONENT REPAIR............................................................................................. 883 BLEEDDOWN MANIFOLD VALVE.................................................................................................. 883 Removal............................................................................................................... 883 Installation.......................................................................................................... 884 FLOW AMPLIFIER............................................................................................................ 885 Removal............................................................................................................... 885 Installation.......................................................................................................... 885 Disassembly........................................................................................................... 885 Assembly.............................................................................................................. 887 STEERING CYLINDERS........................................................................................................ 888 Disassembly........................................................................................................... 889 Piston Seal & Bearing Installation.................................................................................... 889 Assembly.............................................................................................................. 889 Testing............................................................................................................... 889 STEERING AND BRAKE PUMP................................................................................................... 890 Removal............................................................................................................... 890 Installation.......................................................................................................... 891 Disassembly........................................................................................................... 892 Inspection............................................................................................................ 895 Assembly.............................................................................................................. 898 Driveshaft Group...................................................................................................... 899 Rotating Group........................................................................................................ 899 Valve Plate Group..................................................................................................... 900 STEERING ACCUMULATORS..................................................................................................... 902 Removal............................................................................................................... 902 Installation.......................................................................................................... 902 Disassembly........................................................................................................... 903 Cleaning and Inspection............................................................................................... 903 Assembly.............................................................................................................. 904 Leak Testing.......................................................................................................... 906 Charging Procedure.................................................................................................... 907 Precharge Maintenance................................................................................................. 909 Accumulator Storage Procedures........................................................................................ 910 Bladder Storage Procedures............................................................................................ 910 Installing A Bladder Accumulator From Storage......................................................................... 910 TROUBLESHOOTING CHART......................................................................................................... 911 SECTION L7 HOIST CIRCUIT.......................................................................................................... 915 HOIST CIRCUIT................................................................................................................. 917 BASIC OPERATION........................................................................................................... 917 COMPONENT DESCRIPTION..................................................................................................... 918 Hydraulic Tank........................................................................................................ 918 Hydraulic Pump........................................................................................................ 918 High Pressure Filters................................................................................................. 918 Hoist Valve........................................................................................................... 918 Inlet Sections........................................................................................................ 918 Work Ports (Rear) Spool Section....................................................................................... 919 Tank Ports (Front) Spool Section...................................................................................... 919 Hoist Pilot Valve..................................................................................................... 919 Bleeddown Manifold.................................................................................................... 920 Hoist Up Limit Solenoid............................................................................................... 920 Pilot Operated Check Valve............................................................................................ 920 Overcenter Manifold................................................................................................... 920 HOIST CIRCUIT OPERATION....................................................................................................... 921 Float Position Of Pilot Valve With Truck Body On Frame.................................................................... 922 Power Up Operation........................................................................................................ 924 Hold Operation............................................................................................................ 926 Power Down Operation...................................................................................................... 928 Float Operation........................................................................................................... 930 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR......................................................................................... 933 HOIST CIRCUIT COMPONENT REPAIR................................................................................................ 935 HOIST VALVE............................................................................................................... 935 Removal............................................................................................................... 935 Installation.......................................................................................................... 936 O-Ring Replacement.................................................................................................... 936 INLET SECTION............................................................................................................. 937 Cleaning and Inspection............................................................................................... 938 Assembly.............................................................................................................. 938 REAR SPOOL SECTION (Work Ports)........................................................................................... 939 Disassembly........................................................................................................... 939 Cleaning and Inspection............................................................................................... 939 Assembly.............................................................................................................. 941 FRONT SPOOL SECTION (Tank Ports).......................................................................................... 942 Disassembly........................................................................................................... 942 Cleaning and Inspection............................................................................................... 942 Assembly.............................................................................................................. 942 HOIST PILOT VALVE......................................................................................................... 944 Removal............................................................................................................... 944 Installation.......................................................................................................... 944 Disassembly........................................................................................................... 945 Cleaning and Inspection............................................................................................... 946 Assembly.............................................................................................................. 946 HOIST CYLINDERS........................................................................................................... 947 Removal............................................................................................................... 947 Installation.......................................................................................................... 948 Disassembly........................................................................................................... 950 Cleaning and Inspection............................................................................................... 951 Assembly - Quill...................................................................................................... 952 Assembly - Cylinder................................................................................................... 954 Testing............................................................................................................... 954 OVERCENTER VALVE MANIFOLD................................................................................................. 955 SECTION L9 HYDRAULIC SYSTEM FILTERS............................................................................................... 957 HYDRAULIC SYSTEM FILTERS...................................................................................................... 959 HOIST CIRCUIT FILTER...................................................................................................... 959 Filter Element Replacement............................................................................................ 959 Removal - Hoist Circuit Filter........................................................................................ 960 Installation - Hoist Circuit Filter................................................................................... 960 Indicator Switch - Hoist Circuit Filter............................................................................... 960 STEERING CIRCUIT FILTER................................................................................................... 961 Filter Element Replacement............................................................................................ 961 Removal - Steering Circuit Filter..................................................................................... 962 Installation - Steering Circuit Filter................................................................................ 962 Indicator Switch - Steering Circuit Filter............................................................................ 962 INDICATOR SWITCH.......................................................................................................... 962 Test Procedure........................................................................................................ 962 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE.......................................................................................... 965 HYDRAULIC CHECKOUT PROCEDURE.................................................................................................. 967 GENERAL INFORMATION....................................................................................................... 967 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................................................... 974 Equipment Requirements................................................................................................ 975 Pump Pressure Control Adjustments..................................................................................... 975 Steering Control Valve and Flow Amplifier Leakage Test................................................................ 976 Bleeddown Manifold Leakage Test....................................................................................... 977 STEERING/BRAKE PUMP STROKE ADJUSTMENT..................................................................................... 978 SHOCK AND SUCTION VALVES.................................................................................................. 978 Equipment Requirements................................................................................................ 978 Pressure Tests........................................................................................................ 978 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES............................................................. 980 Equipment Requirements................................................................................................ 980 Pressure Gauge Locations.............................................................................................. 980 Brake Cooling Circuit Test............................................................................................ 980 Power Up Relief Pressure Test......................................................................................... 981 Power Down Relief Pressure Test....................................................................................... 982 Counterbalance Valve Pressure Check................................................................................... 983 Counterbalance Valve Adjustment....................................................................................... 984 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET......................................................................... 985 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET............................................................ 986 SECTION M OPTIONS AND SPECIAL TOOLS................................................................................................... 987 SECTION M7 HOT START SYSTEM....................................................................................................... 989 HOT START SYSTEM.............................................................................................................. 991 SYSTEM OPERATION.......................................................................................................... 991 HEATER INFORMATION........................................................................................................ 992 TROUBLESHOOTING GUIDELINES................................................................................................ 993 SECTION M8 SPECIAL TOOLS.......................................................................................................... 995 HIGH VOLTAGE TOOLS............................................................................................................1000 0-2000 VDC CUSTOM METER KIT (58B-06-00800)....................................................................................1000 SECTION M19 RADIATOR SHUTTERS.....................................................................................................1003 RADIATOR SHUTTERS.............................................................................................................1005 OPERATION.................................................................................................................1005 Hydraulic Circuit.....................................................................................................1005 Electrical Circuit....................................................................................................1006 MAINTENANCE AND REPAIR....................................................................................................1006 TROUBLESHOOTING...........................................................................................................1007 SECTION M20 PAYLOAD METER III ™...................................................................................................1011 OPERATION SECTION.............................................................................................................1015 Introduction..............................................................................................................1015 Data Summary..........................................................................................................1015 Data Gathering........................................................................................................1015 COMPONENT DESCRIPTION.....................................................................................................1016 System Diagram........................................................................................................1016 Suspension Pressure Sensors...........................................................................................1016 Inclinometer..........................................................................................................1016 Operator Display......................................................................................................1016 Operator Switch.......................................................................................................1017 Speed Input...........................................................................................................1017 Body-Up Switch........................................................................................................1017 Brake Lock Switch.....................................................................................................1017 Payload Meter.........................................................................................................1017 Communications Ports..................................................................................................1017 Key Switch Input......................................................................................................1018 Payload Meter Power...................................................................................................1018 Load Lights...........................................................................................................1018 Wiring and Termination................................................................................................1019 TCI Outputs...........................................................................................................1019 OPERATOR’S DISPLAY AND SWITCH.............................................................................................1020 Reading the Speedometer...............................................................................................1020 Reading the Load Display..............................................................................................1020 Using the Operator ID.................................................................................................1020 Using the Load and Ton Counter........................................................................................1020 Total Ton Counter.....................................................................................................1020 Total Load Counter....................................................................................................1021 Clearing the Counters.................................................................................................1021 Viewing Live Sensor Data..............................................................................................1021 Other Display Messages................................................................................................1021 PAYLOAD OPERATION & CALCULATION...........................................................................................1022 Description of Haul Cycle States......................................................................................1022 Haul Cycle Description................................................................................................1022 Load Calculation......................................................................................................1023 Carry Back............................................................................................................1023 Measurement Accuracy..................................................................................................1023 SOURCES FOR PAYLOAD ERROR.................................................................................................1023 Payload Error.........................................................................................................1023 Loading Conditions....................................................................................................1024 Pressure Sensors......................................................................................................1024 Swingloads............................................................................................................1024 Speed and Distance....................................................................................................1024 HAUL CYCLE DATA...........................................................................................................1024 Haul Cycle Warning Flags..............................................................................................1026 Frame Torque Data.....................................................................................................1027 Sprung Weight Data....................................................................................................1027 Maximum Speed Data....................................................................................................1027 Alarm Records.........................................................................................................1027 Fault Code Data.......................................................................................................1028 PC SOFTWARE OVERVIEW......................................................................................................1029 System Configuration..................................................................................................1029 Installing the PLMIII Software........................................................................................1029 DOWNLOADING DATA..........................................................................................................1030 PLM III SYSTEM CONFIGURATION..............................................................................................1031 Starting Communications...............................................................................................1031 Displayed Payload Units...............................................................................................1031 Time Units............................................................................................................1031 Connection Menu.......................................................................................................1031 Connecting to the Payload Meter.......................................................................................1032 Configure the Payload Meter...........................................................................................1032 Setting the Date and Time.............................................................................................1032 Setting the Truck Type................................................................................................1033 Setting the Gauge Display Units.......................................................................................1033 Setting the Frame Serial Number.......................................................................................1033 Setting the Truck Number..............................................................................................1033 Setting the Komatsu Distributor.......................................................................................1033 Setting the Komatsu Customer..........................................................................................1033 Clean Truck Tare Calibration..........................................................................................1034 Inclinometer Calibration..............................................................................................1034 DATA ANALYSIS.............................................................................................................1035 Creating a Query......................................................................................................1035 Sorting on Truck Unit Number..........................................................................................1035 Sorting on Truck Type.................................................................................................1035 Sorting on Date Range.................................................................................................1036 Sorting on Time Range.................................................................................................1036 Payload Detail Screen.................................................................................................1037 Creating Reports......................................................................................................1037 Summary - one page report.............................................................................................1038 Detailed - multi-page report..........................................................................................1038 Creating Graphs.......................................................................................................1039 Exporting Data........................................................................................................1039 CSV Export............................................................................................................1039 Compressed............................................................................................................1040 Importing Data........................................................................................................1041 Deleting Haul Cycle Records...........................................................................................1041 Viewing Alarms........................................................................................................1042 Deleting Alarm Records................................................................................................1042 TROUBLESHOOTING SECTION.......................................................................................................1043 TROUBLESHOOTING...........................................................................................................1043 Viewing Active Alarms.................................................................................................1043 Real-Time Data Display................................................................................................1043 Testing the Payload Lights............................................................................................1043 Creating Log Files of Inputs..........................................................................................1044 Daily Inspections.....................................................................................................1044 Periodic Maintenance..................................................................................................1044 Abnormal Displays at Power-Up.........................................................................................1045 No Payload Display When Key Switch is Turned ON.......................................................................1046 No Display on Speedometer.............................................................................................1047 No Display on Operator Display........................................................................................1047 No Communications With PC.............................................................................................1048 Load Lights Don’t Light During Loading................................................................................1049 Load Lights Remain ON.................................................................................................1050 Load Lights Remain ON During Dumping..................................................................................1050 Display Doesn't Clear When The Load Is Dumped.........................................................................1050 Calibration Problems..................................................................................................1051 Alarm 1 - Left Front Pressure High....................................................................................1052 Alarm 2 - Left Front Pressure Low.....................................................................................1052 Troubleshoot Wiring to Left Front Suspension..........................................................................1052 Alarm 3 - Right Front Pressure High...................................................................................1053 Alarm 4 - Right Front Pressure Low....................................................................................1053 Troubleshoot Wiring to Right Front Suspension.........................................................................1053 Alarm 5 -Left Rear Pressure High......................................................................................1054 Alarm 6 - Left Rear Pressure Low......................................................................................1054 Troubleshoot Wiring to Left Rear Suspension...........................................................................1054 Alarm 7 - Right Rear Pressure High....................................................................................1055 Alarm 8 - Right Rear Pressure Low.....................................................................................1055 Troubleshoot Wiring to Right Rear Suspension..........................................................................1055 Alarm 9 - Inclinometer High...........................................................................................1056 Alarm 10 - Inclinometer Low...........................................................................................1056 Troubleshoot Inclinometer Wiring......................................................................................1056 Alarm 13 - Body Up Input Failure......................................................................................1057 Alarm 16 - Memory Write Failure.......................................................................................1058 Alarm 17 - Memory Read Failure........................................................................................1058 Alarm 18..............................................................................................................1059 Alarm 19..............................................................................................................1059 Alarm 22..............................................................................................................1059 Operator Switch Doesn't Work..........................................................................................1060 Alarm 26 - User Switch Fault - SELECT.................................................................................1060 Alarm 27 - User Switch Fault - SET....................................................................................1060 Connector Map.........................................................................................................1061 Connectors............................................................................................................1062 PLMIII CHECK OUT PROCEDURE....................................................................................................1063 General Description.......................................................................................................1063 Tools Required............................................................................................................1063 Checkout Procedure........................................................................................................1063 PLMIII CHECKOUT PROCEDURE CONFIRMATION....................................................................................1067 Flashburn Programming.................................................................................................1067 Confirmation Checklist................................................................................................1069 SECTION M31 RESERVE ENGINE OIL SYSTEM.............................................................................................1071 RESERVE ENGINE OIL SYSTEM.....................................................................................................1073 Operation.................................................................................................................1074 LED Monitor Light.........................................................................................................1074 Tank Fill Control (Optional)..............................................................................................1075 Filling Procedure (Remote Fill Feature)...................................................................................1075 SERVICE...................................................................................................................1076 Every 10 Hours, or once each shift:...................................................................................1076 Every 500 Hours.......................................................................................................1076 Changing Oil..........................................................................................................1076 TROUBLESHOOTING...........................................................................................................1077 Circuit Fuse..........................................................................................................1077 SYSTEM ELECTRICAL SCHEMATICS..............................................................................................1078 SECTION N OPERATOR CAB................................................................................................................1079 SECTION N2 TRUCK CAB AND COMPONENTS...............................................................................................1081 TRUCK CAB AND COMPONENTS......................................................................................................1083 TRUCK CAB.................................................................................................................1083 Description...........................................................................................................1083 Removal...............................................................................................................1084 Installation..........................................................................................................1085 CAB DOOR..................................................................................................................1086 Removal...............................................................................................................1086 Installation..........................................................................................................1086 Door Jamb Bolt Adjustment.............................................................................................1087 Door Handle Plunger Adjustment........................................................................................1088 Replacing the Door Glass..............................................................................................1089 Replacing the Door Handle or Latch Assembly...........................................................................1093 Replacing the Door Window Regulator...................................................................................1094 Replacing the Door and Door Hinge Seal................................................................................1095 Replacing the Door Opening Seal.......................................................................................1095 GLASS REPLACEMENT (Adhesive-Bonded Windows)...............................................................................1096 Recommended Tools and Supplies........................................................................................1096 Replacement Procedure.................................................................................................1096 WINDSHIELD AND REAR GLASS.................................................................................................1097 Removal...............................................................................................................1097 Installation..........................................................................................................1098 SECTION N3 CAB COMPONENTS.........................................................................................................1099 CAB COMPONENTS................................................................................................................1101 WINDSHIELD WIPERS.........................................................................................................1101 WIPER MOTOR...........................................................................................................1101 Removal...........................................................................................................1101 Installation......................................................................................................1101 WIPER ARM.............................................................................................................1101 Removal...........................................................................................................1101 Installation......................................................................................................1102 WIPER LINKAGE.........................................................................................................1102 Removal...........................................................................................................1102 Installation......................................................................................................1102 WINDSHIELD WASHER.........................................................................................................1103 Operation.............................................................................................................1103 Service...............................................................................................................1103 OPERATOR SEAT.............................................................................................................1104 Adjustment............................................................................................................1104 Inspection............................................................................................................1105 Removal...............................................................................................................1105 Installation..........................................................................................................1105 PASSENGER SEAT............................................................................................................1106 Inspection............................................................................................................1106 Removal...............................................................................................................1106 Installation..........................................................................................................1106 SEAT BELT.................................................................................................................1107 Removal...............................................................................................................1107 Installation..........................................................................................................1107 SECTION N4 HEATER / AIR CONDITIONER...............................................................................................1109 HEATER/AIR CONDITIONER........................................................................................................1111 OPERATION.................................................................................................................1111 Fan Speed Control Knob................................................................................................1111 Temperature Control Knob..............................................................................................1111 Air Flow Directional Knob.............................................................................................1112 Heater/Air Conditioner Vents..........................................................................................1112 COMPONENTS................................................................................................................1112 Fuse and Circuit Breaker..............................................................................................1112 Relays................................................................................................................1112 Heater Core...........................................................................................................1113 Fan Motor And Speed Control...........................................................................................1113 Actuators.............................................................................................................1113 Cab Air Filter........................................................................................................1113 ENVIRONMENTAL IMPACT OF AIR CONDITIONING..................................................................................1116 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.................................................................................1116 PRINCIPLES OF REFRIGERATION...............................................................................................1116 Air Conditioning......................................................................................................1116 Refrigeration - The Act Of Cooling....................................................................................1117 The Refrigeration Cycle...............................................................................................1117 AIR CONDITIONER SYSTEM COMPONENTS.........................................................................................1118 Compressor (Refrigerant Pump).........................................................................................1118 Service Valves........................................................................................................1118 Condenser.............................................................................................................1118 Receiver-Drier........................................................................................................1118 Expansion Block Valve.................................................................................................1119 Accumulator...........................................................................................................1119 Evaporator............................................................................................................1119 ELECTRICAL CIRCUIT........................................................................................................1120 Thermostat............................................................................................................1120 Compressor Clutch.....................................................................................................1120 Trinary™ Switch.......................................................................................................1121 AIR CONDITIONING SYSTEM SERVICING WARNINGS................................................................................1122 SERVICE TOOLS AND EQUIPMENT...............................................................................................1123 Recovery/Recycle Station..............................................................................................1123 Leak Detector.........................................................................................................1123 Manifold Gauge Set....................................................................................................1124 Installing Manifold Gauge Set.........................................................................................1125 Purging Air From Service Hoses........................................................................................1125 Service Valves........................................................................................................1126 Vacuum Pump...........................................................................................................1126 SYSTEM PERFORMANCE TEST...................................................................................................1127 SYSTEM OIL................................................................................................................1128 Handling and Reusing PAG Oil..........................................................................................1128 Oil Quantity..........................................................................................................1128 Checking System Oil...................................................................................................1128 REFRIGERANT...............................................................................................................1129 Recycled Refrigerant..................................................................................................1129 Reclaimed Refrigerant.................................................................................................1129 Refrigerant Quantity..................................................................................................1130 R-134a Refrigerant Containers.........................................................................................1130 SYSTEM LEAK TESTING.......................................................................................................1130 Electronic Leak Detector..............................................................................................1131 Tracer Dyes...........................................................................................................1131 Soap and Water........................................................................................................1131 RECOVERING AND RECYCLING THE REFRIGERANT..................................................................................1131 Draining Oil from the Previous Recovery Cycle.........................................................................1131 Performing the Recovery Cycle.........................................................................................1131 Performing the Recycling Procedure....................................................................................1132 Evacuating and Charging the A/C System................................................................................1132 SYSTEM REPAIR.............................................................................................................1132 System Flushing.......................................................................................................1132 A/C DRIVE BELT CHECKOUT PROCEDURE.........................................................................................1133 Pulley Alignment......................................................................................................1133 Belt Tension Check....................................................................................................1133 COMPONENT REPLACEMENT.....................................................................................................1135 Hoses and Fittings....................................................................................................1135 Lines.................................................................................................................1135 Expansion Valve.......................................................................................................1135 Receiver-Drier........................................................................................................1135 Thermostat............................................................................................................1135 Compressor............................................................................................................1136 Accumulator...........................................................................................................1136 Clutch................................................................................................................1136 Servicing the Compressor Clutch.......................................................................................1137 Pulley Removal........................................................................................................1139 Clutch Coil Check.....................................................................................................1139 Pulley Installation...................................................................................................1139 Clutch Assembly Installation..........................................................................................1140 EVACUATING THE SYSTEM.....................................................................................................1141 CHARGING THE A/C SYSTEM...................................................................................................1142 TROUBLESHOOTING...........................................................................................................1143 Preliminary Checks....................................................................................................1143 Diagnosis Of Gauge Readings And System Performance....................................................................1143 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................................................................1144 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM................................................................................1150 SECTION N5 OPERATOR CAB CONTROLS..................................................................................................1151 OPERATOR CAB CONTROLS.........................................................................................................1154 STEERING COLUMN...........................................................................................................1155 Removal...............................................................................................................1155 Inspection............................................................................................................1155 Installation..........................................................................................................1156 STEERING WHEEL............................................................................................................1156 Removal...............................................................................................................1156 Installation..........................................................................................................1156 STEERING WHEEL AND CONTROLS...............................................................................................1158 Horn Button...........................................................................................................1158 Tilt / Telescope Lever................................................................................................1158 Multi-Function Turn Signal Switch.....................................................................................1158 DYNAMIC RETARDING.........................................................................................................1159 Retarder Lever........................................................................................................1159 Brake/Retarder Pedal..................................................................................................1159 Throttle/Accelerator Pedal............................................................................................1159 GRADE/SPEED CHART.........................................................................................................1160 OVERHEAD PANEL AND DISPLAYS...............................................................................................1161 Speakers..............................................................................................................1161 Warning Alarm Buzzer..................................................................................................1161 Radio/CD Player.......................................................................................................1161 Warning Indicator Light Dimmer Control................................................................................1161 Status/Warning Indicator Light Panel..................................................................................1161 Air Cleaner Restriction Gauges........................................................................................1161 CENTER CONSOLE............................................................................................................1162 Directional Control Lever.............................................................................................1162 Override/Fault Reset Switch...........................................................................................1163 Engine Shutdown Switch................................................................................................1163 Window Control Switches...............................................................................................1163 Hoist Control Lever...................................................................................................1163 Retarder Speed Control (RSC) Adjustment Dial..........................................................................1164 Retarder Speed Control (RSC) Switch...................................................................................1164 Data Store Button.....................................................................................................1165 KOMTRAX Plus Snapshot In Progress Light...............................................................................1165 Link Energized Light..................................................................................................1165 Service Engine Light..................................................................................................1165 12V Auxiliary Power Outlets...........................................................................................1165 DIAGNOSTIC PORTS..........................................................................................................1165 KOMTRAX Plus Diagnostic Port..........................................................................................1165 Interface Module (IM) Diagnostic Port.................................................................................1165 Payload Meter Diagnostic Port.........................................................................................1165 Truck Control Interface (TCI) Diagnostic Port.........................................................................1165 Propulsion System Controller (PSC) Diagnostic Port....................................................................1165 Engine Diagnostic Port (CENSE)........................................................................................1165 Engine Diagnostic Port (QUANTUM)......................................................................................1165 INSTRUMENT PANEL..........................................................................................................1166 Control Symbols.......................................................................................................1166 Key Switch............................................................................................................1168 Rotating Beacon Switch (optional).....................................................................................1168 Heated Mirrors Switch (optional)......................................................................................1168 AC Drive System Rest Switch...........................................................................................1168 Wheel Brake Lock Switch...............................................................................................1169 Hazard Warning Lights.................................................................................................1169 Heater/Air Conditioner Vents..........................................................................................1169 Engine Oil Pressure Gauge.............................................................................................1169 Right Turn Signal Indicator...........................................................................................1169 Digital Tachometer....................................................................................................1169 High Beam Indicator...................................................................................................1169 Speedometer/Payload Meter Display.....................................................................................1169 Left Turn Signal Indicator............................................................................................1170 Coolant Temperature Gauge.............................................................................................1170 Lamp Check Switch.....................................................................................................1170 Light Switch (3-Way)..................................................................................................1170 Ladder Light Switch...................................................................................................1170 Backup Light Switch...................................................................................................1170 Fog Light Switch......................................................................................................1170 Payload Meter Switch..................................................................................................1171 Panel Illumination Light Dimmer Switch................................................................................1171 Hydraulic Oil Temperature Gauge.......................................................................................1171 Engine Hourmeter......................................................................................................1171 Fuel Gauge............................................................................................................1171 OVERHEAD STATUS / WARNING INDICATORS......................................................................................1172 A1. High Hydraulic Oil Temperature....................................................................................1173 B1. Low Steering Pressure.............................................................................................1173 C1. Low Accumulator Precharge Pressure................................................................................1174 D1. Not used..........................................................................................................1174 E1. Low Brake Pressure................................................................................................1174 A2. Low Hydraulic Tank Level..........................................................................................1174 B2. Low Automatic Lubrication System Pressure.........................................................................1174 C2. Circuit Breaker Tripped...........................................................................................1174 D2. Hydraulic Oil Filter Monitor......................................................................................1175 E2. Low Fuel..........................................................................................................1175 A3. Parking Brake.....................................................................................................1175 B3. Service Brake.....................................................................................................1175 C3. Body Up...........................................................................................................1175 D3. Dynamic Retarding.................................................................................................1175 E3. Stop Engine.......................................................................................................1176 A4. Cranking Motor Failure............................................................................................1176 B4. Backup Lights.....................................................................................................1176 C4. Engine Shutdown Timer.............................................................................................1176 D4. Retard Speed Control (RSC) Indicator..............................................................................1176 E4. Check Engine......................................................................................................1176 A5. No Power..........................................................................................................1177 B5. Propulsion System Warning.........................................................................................1177 C5. Propulsion System Temperature.....................................................................................1177 D5. System/Component Failure..........................................................................................1177 E5. Battery Charging System Failure...................................................................................1177 A6. No Propel.........................................................................................................1177 B6. Propel System At Rest.............................................................................................1177 C6. Propel System Not Ready...........................................................................................1178 D6. Reduced Propulsion................................................................................................1178 E6. Retard At Continuous Level........................................................................................1178 REAR AXLE LIGHT BAR.......................................................................................................1179 Backup Lights.........................................................................................................1179 Retard Lights.........................................................................................................1179 Brake Light...........................................................................................................1179 Backup Alarm..........................................................................................................1179 KOMTRAX PLUS..............................................................................................................1180 Operation.............................................................................................................1180 Interface Module......................................................................................................1182 Basic Precautions.....................................................................................................1182 KOMATSU WIRELESS BRIDGE (Optional)........................................................................................1183 General Information...................................................................................................1183 Communication Setup...................................................................................................1183 Switching to the KWB_SETUP Network....................................................................................1183 Setting the Computer Subnet Mask and IP Address.......................................................................1184 Properties............................................................................................................1184 Setting Up the KWB....................................................................................................1185 Adding Encryption.....................................................................................................1185 Final Computer Settings...............................................................................................1185 Data Downloading......................................................................................................1186 Resetting the KWB.....................................................................................................1186 KWB Lights............................................................................................................1186 SECTION P LUBRICATION AND SERVICE.....................................................................................................1187 SECTION P2 LUBRICATION AND SERVICE................................................................................................1189 LUBRICATION AND SERVICE.......................................................................................................1191 GENERAL...................................................................................................................1191 SERVICE CAPACITIES........................................................................................................1191 HYDRAULIC TANK SERVICE....................................................................................................1191 Adding Oil............................................................................................................1191 COOLING SYSTEM SERVICE....................................................................................................1192 Radiator Filling Procedure............................................................................................1192 Coolant Specifications................................................................................................1192 Unacceptable Practices................................................................................................1192 WHEEL MOTOR SERVICE.......................................................................................................1192 RESERVE OIL TANK SERVICE..................................................................................................1193 Filling the Reserve Oil Tank (Remote Fill)............................................................................1193 Inline Screen.........................................................................................................1193 QUICK FILL SERVICE CENTER.................................................................................................1194 LUBRICATION CHART.........................................................................................................1195 10 HOUR (DAILY) INSPECTIONS...............................................................................................1196 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................1199 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1199 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1199 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1202 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................1204 5000 HOUR MAINTENANCE CHECKS..............................................................................................1204 SECTION P3 AUTOMATIC LUBRICATION SYSTEM...........................................................................................1205 AUTOMATIC LUBRICATION SYSTEM..................................................................................................1207 GENERAL DESCRIPTION.......................................................................................................1207 SYSTEM COMPONENTS.........................................................................................................1209 Filter................................................................................................................1209 Hydraulic Motor and Pump..............................................................................................1209 Grease Reservoir......................................................................................................1209 Pressure Reducing Valve...............................................................................................1209 Flow Control Valve....................................................................................................1209 Solenoid Valve........................................................................................................1209 Vent Valve............................................................................................................1209 Lubrication Cycle Timer...............................................................................................1209 Over Pressure Cut Off Switch..........................................................................................1209 Grease Pressure Failure Switch........................................................................................1209 Injectors.............................................................................................................1209 Relief Valve (unloader valve).........................................................................................1209 SYSTEM OPERATION..........................................................................................................1210 Normal Operation......................................................................................................1210 Lubricant Required For System.........................................................................................1211 System Priming........................................................................................................1211 Filter Assembly.......................................................................................................1211 LUBRICANT PUMP............................................................................................................1212 Pump Housing Oil Level................................................................................................1212 Pump Pressure Control.................................................................................................1212 INJECTORS (SL-1 Series “H”)...............................................................................................1213 Injector Specifications...............................................................................................1213 Injector Adjustment...................................................................................................1213 INJECTOR OPERATION....................................................................................................1214 PREVENTIVE MAINTENANCE PROCEDURES.........................................................................................1215 Daily Lubrication System Inspection...................................................................................1215 250 Hour Inspection...................................................................................................1215 1000 Hour Inspection..................................................................................................1215 SYSTEM CHECKOUT...........................................................................................................1216 Lubrication Controller Check..........................................................................................1216 Lubrication Controller Components.....................................................................................1216 Lubrication Controller Adjustment.....................................................................................1216 SYSTEM TROUBLESHOOTING CHART..................................................................................................1218 SECTION Q ALPHABETICAL INDEX..........................................................................................................1221 SECTION R SYSTEM SCHEMATICS...........................................................................................................1225 HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC.......................................................................1227 HYDRAULIC BRAKE SYSTEM SCHEMATIC..................................................................................................1228 ELECTRICAL SCHEMATICS.............................................................................................................1229
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