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KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30796 A31001) – PDF DOWNLOAD
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- KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30796 A31001
- PUBLICATION NUMBER:CEBM022105
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Description
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30796 A31001)
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30796 A31001) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30796 A31001)
- 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:A30796 A31001)
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................................................................................................................. 113 Body Pad Shimming Procedure........................................................................................... 114 BODY GUIDE................................................................................................................ 115 HOIST LIMIT SWITCH........................................................................................................ 115 BODY-UP SWITCH............................................................................................................ 115 BODY RETENTION SLING...................................................................................................... 115 ROCK EJECTORS............................................................................................................. 116 Inspection............................................................................................................ 116 SECTION B4 FUEL TANK.............................................................................................................. 117 FUEL TANK..................................................................................................................... 119 FUEL TANK................................................................................................................. 119 Removal............................................................................................................... 119 Repair................................................................................................................ 119 Cleaning.............................................................................................................. 119 Installation.......................................................................................................... 119 FUEL TANK VENT ASSEMBLY................................................................................................... 121 Disassembly........................................................................................................... 121 Assembly.............................................................................................................. 121 FUEL GAUGE SENDER......................................................................................................... 122 Removal............................................................................................................... 122 Installation.......................................................................................................... 122 QUICK FILL FUEL RECEIVERS................................................................................................. 122 SECTION C ENGINE...................................................................................................................... 123 SECTION C2 POWER MODULE........................................................................................................... 125 POWER MODULE.................................................................................................................. 127 PREPARATION FOR REMOVAL................................................................................................... 127 REMOVAL................................................................................................................... 132 INSTALLATION.............................................................................................................. 134 HOOKUP.................................................................................................................... 135 SECTION C3 COOLING SYSTEM......................................................................................................... 137 COOLING SYSTEM................................................................................................................ 139 RADIATOR.................................................................................................................. 139 Removal............................................................................................................... 139 Installation.......................................................................................................... 141 Filling Procedure..................................................................................................... 142 REPAIRING THE RADIATOR.................................................................................................... 142 Internal Inspection................................................................................................... 142 External Cleaning..................................................................................................... 142 Disassembly........................................................................................................... 143 Cleaning and Inspection............................................................................................... 144 Assembly.............................................................................................................. 144 Pressure Testing...................................................................................................... 145 COOLANT SYSTEM TROUBLESHOOTING............................................................................................ 145 SECTION C4 POWER TRAIN............................................................................................................ 147 POWER TRAIN................................................................................................................... 149 ALTERNATOR REMOVAL........................................................................................................ 149 ALTERNATOR INSTALLATION................................................................................................... 151 Measuring Procedure................................................................................................... 151 Joining the Alternator and Engine..................................................................................... 153 ENGINE.................................................................................................................... 154 Removal............................................................................................................... 154 Service............................................................................................................... 154 Installation.......................................................................................................... 154 SECTION C5 AIR CLEANERS........................................................................................................... 155 AIR CLEANERS.................................................................................................................. 157 OPERATION................................................................................................................. 157 SERVICING THE AIR CLEANERS................................................................................................ 157 Replacing The Filter Element.......................................................................................... 157 Cleaning The Main Filter Element...................................................................................... 159 Servicing The Precleaner Section...................................................................................... 160 EVACUATOR VALVES (if equipped)............................................................................................ 161 AIR INTAKE TROUBLESHOOTING................................................................................................ 161 SECTION C5 AIR CLEANERS........................................................................................................... 163 AIR CLEANERS.................................................................................................................. 165 OPERATION................................................................................................................. 165 SERVICING THE AIR CLEANERS................................................................................................ 165 Replacing The Elements................................................................................................ 166 AIR CLEANER ASSEMBLY CLEANING............................................................................................. 167 Primary Element Cleaning.............................................................................................. 167 Precleaner Section Cleaning........................................................................................... 169 AIR INTAKE TROUBLESHOOTING................................................................................................ 170 SECTION C7 FAN CLUTCH............................................................................................................. 171 FAN CLUTCH.................................................................................................................... 173 REMOVAL & INSTALLATION TOOLING............................................................................................ 173 DISASSEMBLY............................................................................................................... 176 CLEANING AND INSPECTION................................................................................................... 186 ASSEMBLY.................................................................................................................. 190 TEST PROCEDURE............................................................................................................ 204 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION).................................................................................... 205 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM........................................................................................... 207 24VDC ELECTRIC SUPPLY SYSTEM.................................................................................................. 209 ELECTRICAL SYSTEM DESCRIPTION............................................................................................. 209 BATTERIES................................................................................................................. 209 Maintenance and Service............................................................................................... 209 Troubleshooting....................................................................................................... 209 BATTERY SUPPLY SYSTEM..................................................................................................... 211 24VDC Battery Charging Alternator..................................................................................... 211 Batteries............................................................................................................. 211 24VDC Auxiliary Battery Receptacles................................................................................... 211 Battery Disconnect Switches........................................................................................... 212 Isolation Diode (if equipped)......................................................................................... 212 Engine Start Relay.................................................................................................... 212 24VDC to 12VDC Converter.............................................................................................. 212 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)....................................................................... 213 Operation............................................................................................................. 213 Pressure Switch....................................................................................................... 213 Check Valve........................................................................................................... 213 Timer Solenoid........................................................................................................ 213 MAINTENANCE............................................................................................................... 214 Prelube System Operation Checks....................................................................................... 214 Check Valve........................................................................................................... 214 Timer Solenoid........................................................................................................ 214 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT................................................................................ 215 24VDC ELECTRIC START SYSTEM................................................................................................... 217 CRANKING MOTORS........................................................................................................... 217 Operation............................................................................................................. 217 Removal............................................................................................................... 217 Installation.......................................................................................................... 217 CRANKING MOTOR TROUBLESHOOTING............................................................................................ 218 Preliminary Inspection................................................................................................ 218 No-Load Test.......................................................................................................... 218 Interpreting Results of Tests......................................................................................... 219 Disassembly........................................................................................................... 219 Cleaning and Inspection............................................................................................... 220 Armature Servicing.................................................................................................... 222 Field Coil Checks..................................................................................................... 222 Field Coil Removal.................................................................................................... 222 SOLENOID CHECKS........................................................................................................... 223 Test.................................................................................................................. 223 Assembly.............................................................................................................. 224 Bearing Replacement:.................................................................................................. 224 Motor Assembly:....................................................................................................... 224 Pinion Clearance...................................................................................................... 225 MAGNETIC SWITCH........................................................................................................... 225 Removal............................................................................................................... 225 Installation.......................................................................................................... 225 Coil Test............................................................................................................. 226 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS..................................................................................... 227 24 VDC ELECTRICAL SYSTEM COMPONENTS........................................................................................... 229 BRAKE WARNING BUZZER...................................................................................................... 229 AUXILIARY CONTROL CABINET COMPONENTS...................................................................................... 229 Power Distribution Terminals.......................................................................................... 229 Control Power Relay................................................................................................... 229 Auto Lube Timer....................................................................................................... 229 Ground Level Power Relay.............................................................................................. 229 Diode Board - DB1..................................................................................................... 231 Fuse Blocks........................................................................................................... 232 Alarm Indicating Device (AID) System.................................................................................. 232 RELAY BOARDS.............................................................................................................. 235 Relay Boards RB1, RB3, RB4, RB5....................................................................................... 235 Relay Board RB6, RB7, RB8, RB9........................................................................................ 237 Relay Board Functions................................................................................................. 238 BODY-UP SWITCH............................................................................................................ 240 Operation............................................................................................................. 240 Adjustment............................................................................................................ 240 Service............................................................................................................... 240 HOIST LIMIT SWITCH........................................................................................................ 242 Operation............................................................................................................. 242 Adjustment............................................................................................................ 242 Service............................................................................................................... 242 FUSE BLOCKS AND CIRCUIT BREAKERS.......................................................................................... 244 SECTION D11 KOMTRAX PLUS.......................................................................................................... 247 KOMTRAX PLUS.................................................................................................................. 249 KOMTRAX PLUS BASIC FEATURES............................................................................................... 249 Gather Data........................................................................................................... 249 Convert and Record Data............................................................................................... 249 Communicate Data to Off-Board Systems................................................................................. 250 USING KOMTRAX PLUS........................................................................................................ 251 Turning KOMTRAX Plus ON............................................................................................... 251 Normal KOMTRAX Plus Operation......................................................................................... 251 Turning KOMTRAX Plus OFF.............................................................................................. 252 Downloading from the KOMTRAX Plus Controller.......................................................................... 252 KOMTRAX PLUS DATA ITEMS................................................................................................... 253 Fault Codes........................................................................................................... 253 Machine History....................................................................................................... 253 KOMTRAX Plus History.................................................................................................. 253 Snapshots............................................................................................................. 254 Manual Snapshots...................................................................................................... 254 Trends................................................................................................................ 256 Histogram (Load Map) Data............................................................................................. 256 Haul Cycle Data....................................................................................................... 257 Alarm and Snapshot Triggers........................................................................................... 258 Satellite Features.................................................................................................... 258 KOMTRAX PLUS DIAGNOSTIC FEATURES.......................................................................................... 260 Fault History......................................................................................................... 260 LED Digits............................................................................................................ 260 KOMTRAX PLUS CONTROLLER................................................................................................... 260 Removal............................................................................................................... 261 Installation.......................................................................................................... 261 KOMTRAX PLUS SOFTWARE..................................................................................................... 262 VHMS Tool Box Installation............................................................................................ 262 VHMS Setting Tool Installation........................................................................................ 262 PDM Software Installation............................................................................................. 262 KOMTRAX PLUS INITIALIZATION PROCEDURE..................................................................................... 263 CONTROLLER SETUP PROCEDURE............................................................................................ 263 SNAPSHOT PROCEDURE.................................................................................................... 266 DOWNLOAD PROCEDURE.................................................................................................... 267 FTP UPLOAD PROCEDURE.................................................................................................. 268 INITIALIZATION FORMS.................................................................................................. 269 WHEN REPLACING A KOMTRAX PLUS CONTROLLER.................................................................................. 270 KOMTRAX PLUS CONTROLLER CHECKOUT.......................................................................................... 275 Necessary Equipment................................................................................................... 275 Preliminary........................................................................................................... 275 KOMTRAX Plus Controller Checkout Procedure............................................................................ 276 ORBCOMM CONTROLLER (if equipped).......................................................................................... 278 Removal............................................................................................................... 278 Installation.......................................................................................................... 278 SECTION D12 INTERFACE MODULE...................................................................................................... 279 INTERFACE MODULE.............................................................................................................. 281 Removal................................................................................................................... 281 Installation.............................................................................................................. 281 SENSORS....................................................................................................................... 282 Temperature Sensors....................................................................................................... 282 Pressure Sensors.......................................................................................................... 282 INTERFACE MODULE SOFTWARE..................................................................................................... 283 Flashburn Program Installation............................................................................................ 283 Interface Module Application Code Installation............................................................................ 284 Interface Module Realtime Data Monitor Software........................................................................... 284 INTERFACE MODULE CHECKOUT..................................................................................................... 285 Necessary Equipment....................................................................................................... 285 Preliminary............................................................................................................... 286 Check Digital Inputs To The Interface Module.............................................................................. 287 Check Analog Inputs To The Interface Module............................................................................... 290 Check Serial Interfaces To The Interface Module........................................................................... 290 Check Outputs From The Interface Module................................................................................... 291 SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING..................................................................... 293 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING............................................................................. 295 GENERAL................................................................................................................... 295 TROUBLESHOOTING........................................................................................................... 296 Communications Networks............................................................................................... 296 Coaxial Cable......................................................................................................... 296 FAULT CODES............................................................................................................... 296 Fault History......................................................................................................... 296 KOMTRAX Plus LED Display Fault Codes.................................................................................. 297 Chassis Fault Codes................................................................................................... 298 Engine Fault Codes.................................................................................................... 302 FAULT TREE ANALYSIS....................................................................................................... 308 Unable to connect to KOMTRAX Plus from laptop PC...................................................................... 308 Flashing Error Code N4-23 (PLM III Communications Fault).............................................................. 309 Flashing Error Code N4-22 (Engine Communications Fault)............................................................... 310 No Data Received By WebCARE........................................................................................... 311 Coaxial Cable Troubleshooting......................................................................................... 312 SECTION D14 KOMTRAX PLUS FORMS.................................................................................................... 313 KOMTRAX PLUS FORMS............................................................................................................ 315 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 315 KOMTRAX PLUS DATA DOWNLOAD................................................................................................ 316 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 317 KOMTRAX PLUS INITIALIZATION FORM.......................................................................................... 319 SECTION E ELECTRIC PROPULSION SYSTEM.................................................................................................. 321 SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS.................................................................................. 323 ELECTRICAL PROPULSION SYSTEM COMPONENTS....................................................................................... 325 GENERAL SYSTEM DESCRIPTION................................................................................................ 325 SYSTEM COMPONENTS......................................................................................................... 327 Propulsion System Controller (PSC).................................................................................... 327 Truck Control Interface (TCI)......................................................................................... 328 Diagnostic Information Display (DID) Panel............................................................................ 329 DID Panel Event Codes................................................................................................. 329 PSC SOFTWARE FUNCTIONS.................................................................................................... 348 Input Processing...................................................................................................... 348 State Machine......................................................................................................... 348 DC Link State......................................................................................................... 351 Engine Control........................................................................................................ 352 ALTERNATOR FIELD CONTROL.................................................................................................. 352 Desired Three-Phase Voltage........................................................................................... 352 Desired DC Link Voltage............................................................................................... 352 Self-Load............................................................................................................. 353 Propel Torque Control................................................................................................. 353 Retard Torque Control................................................................................................. 353 Wheel Slide Control................................................................................................... 354 Resistor Grid Control................................................................................................. 354 Chopper Voltage Control............................................................................................... 354 EVENT DETECTION AND PROCESSING............................................................................................ 354 Power-On Tests........................................................................................................ 354 Initiated Tests....................................................................................................... 355 Periodic Tests........................................................................................................ 355 EVENT RESTRICTIONS........................................................................................................ 355 EVENT LOGGING AND STORAGE................................................................................................. 355 Event History Buffer.................................................................................................. 356 Data Packs............................................................................................................ 356 To Record and Save a Data Pack to a Disk.............................................................................. 356 Event Reset........................................................................................................... 357 SERIAL DATA COMMUNICATIONS................................................................................................ 357 PSC - TCI Communications Processing................................................................................... 357 PSC - PTU Communications Processing................................................................................... 357 Inverter Communications Processing.................................................................................... 358 OUTPUT PROCESSING......................................................................................................... 358 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS.................................................................................. 358 Fast Start............................................................................................................ 358 Engine Shutdown/Engine Not Running.................................................................................... 358 Limp Home Mode........................................................................................................ 359 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS..................................................................... 360 ELECTRONIC ACCELERATOR AND RETARD PEDALS.................................................................................. 368 Removal............................................................................................................... 368 Installation.......................................................................................................... 368 Disassembly........................................................................................................... 368 Assembly.............................................................................................................. 368 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.......................................................................... 369 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE................................................................................. 371 AC DRIVE SYSTEM MAINTENANCE............................................................................................... 371 NORMAL TRUCK SHUTDOWN PROCEDURE........................................................................................... 372 SHUTDOWN AFTER SYSTEM FAILURE............................................................................................. 372 SYSTEM CHECKOUT........................................................................................................... 373 Battery and Control Circuit Checks - Battery Power OFF................................................................ 373 Battery and Control Circuit Checks - Battery Power ON................................................................. 376 Checks with Key Switch OFF............................................................................................ 377 Checks with Key Switch ON............................................................................................. 377 CPU Battery Checks.................................................................................................... 377 MEMORY BACKUP BATTERY REPLACEMENT......................................................................................... 378 TCI PROGRAMMING........................................................................................................... 378 PSC PROGRAMMING........................................................................................................... 379 INVERTER PROGRAMMING...................................................................................................... 379 CPU RESET................................................................................................................. 379 PSC CHECKOUT.............................................................................................................. 380 PSC Digital Input Checks.............................................................................................. 380 PSC Digital Output Checks............................................................................................. 384 TCI CHECKOUT.............................................................................................................. 385 Modular Mining Communication Port Check............................................................................... 385 TCI Digital Input Checks.............................................................................................. 385 TCI Digital Output Tests.............................................................................................. 391 CALIBRATIONS.............................................................................................................. 393 Speedometer........................................................................................................... 393 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial.................................................................. 393 ERASING EVENTS............................................................................................................ 393 PSC................................................................................................................... 393 TCI................................................................................................................... 394 GATE DRIVER POWER CONVERTER TEST.......................................................................................... 394 LOAD TESTING.............................................................................................................. 395 Preparation........................................................................................................... 395 Alternator Speed Sensor Checks........................................................................................ 395 Battery Boost Check................................................................................................... 395 Brake Circuit Switch Checks........................................................................................... 396 Hoist & Steering Circuit Switch Checks................................................................................ 396 Link Energized Checks................................................................................................. 396 Loadbox Test.......................................................................................................... 398 TROUBLESHOOTING........................................................................................................... 402 PVM Optimum Load Curve Handshaking Troubleshooting.................................................................... 402 Phase Module and Chopper Module Troubleshooting....................................................................... 402 PHASE MODULE REPLACEMENT.................................................................................................. 403 Phase Module Removal.................................................................................................. 403 Phase Module Installation............................................................................................. 403 SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146)................................................................................ 405 Fault Code A001: Left front suspension pressure sensor signal is high......................................................... 407 Related circuit diagram................................................................................................... 407 Fault Code A002: Left front suspension pressure sensor signal is low.......................................................... 408 Related circuit diagram................................................................................................... 408 Fault Code A003: Right front suspension pressure sensor signal is high........................................................ 409 Related circuit diagram................................................................................................... 409 Fault Code A004: Right front suspension pressure sensor signal is low......................................................... 410 Related circuit diagram................................................................................................... 410 Fault Code A005: Left rear suspension pressure sensor signal is high.......................................................... 411 Related circuit diagram................................................................................................... 411 Fault Code A006: Left rear suspension pressure sensor signal is low........................................................... 412 Related circuit diagram................................................................................................... 412 Fault Code A007: Right rear suspension pressure sensor signal is high......................................................... 413 Related circuit diagram................................................................................................... 413 Fault Code A008: Right rear suspension pressure sensor signal is low.......................................................... 414 Related circuit diagram................................................................................................... 414 Fault Code A009: Incline sensor signal is high................................................................................ 415 Related circuit diagram................................................................................................... 415 Fault Code A010: Incline sensor signal is low................................................................................. 416 Related circuit diagram................................................................................................... 416 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 417 Related circuit diagram................................................................................................... 417 Fault Code A013: Body up switch has failed.................................................................................... 418 Related circuit diagram................................................................................................... 418 Fault Code A014: Payload meter checksum computation has failed................................................................ 419 Related circuit diagram................................................................................................... 419 Fault Code A016: Payload meter write to flash memory has failed............................................................... 420 Related circuit diagram................................................................................................... 420 Fault Code A017: Payload meter flash memory read has failed................................................................... 421 Related circuit diagram................................................................................................... 421 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 422 Related circuit diagram................................................................................................... 423 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 424 Related circuit diagram................................................................................................... 425 Fault Code A022: Carryback load is excessive.................................................................................. 426 Related circuit diagram................................................................................................... 427 Fault Code A026: Payload meter user select switch has failed.................................................................. 428 Related circuit diagram................................................................................................... 428 Fault Code A027: Payload meter user clear switch has failed................................................................... 429 Related circuit diagram................................................................................................... 429 Fault Code A101: High pressure detected across a hydraulic pump filter........................................................ 430 Related circuit diagram................................................................................................... 431 Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level................................... 432 Related circuit diagram................................................................................................... 433 Fault Code A107: GE has generated a propel system caution..................................................................... 434 Related circuit diagram................................................................................................... 435 Fault Code A108: GE has generated a propel system temperature caution......................................................... 436 Related circuit diagram................................................................................................... 437 Fault Code A109: GE has generated a propel system reduced level signal........................................................ 438 Related circuit diagram................................................................................................... 439 Fault Code A115: Low steering precharge pressure is detected.................................................................. 440 Related circuit diagram................................................................................................... 441 Fault Code A123: GE has generated a reduced retarding caution................................................................. 442 Related circuit diagram................................................................................................... 443 Fault Code A124: GE has generated a no propel / no retard warning............................................................. 444 Related circuit diagram................................................................................................... 445 Fault Code A125: GE has generated a no propel warning......................................................................... 446 Related circuit diagram................................................................................................... 447 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 448 Related circuit diagram................................................................................................... 449 Fault Code A127: IM furnished +5 volt output for sensors is low............................................................... 450 Related circuit diagram................................................................................................... 451 Fault Code A128: IM furnished +5 volt output for sensors is high.............................................................. 452 Related circuit diagram................................................................................................... 453 Fault Code A139, A310: Low fuel level warning................................................................................. 454 Related circuit diagram................................................................................................... 455 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 456 Related circuit diagram................................................................................................... 457 Fault Code A146: Hydraulic temperature sensors cause posting of this faultl................................................... 458 Related circuit diagram................................................................................................... 459 SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216)................................................................................ 461 Fault Code A152: Starter failure.............................................................................................. 462 Related circuit diagram................................................................................................... 463 Fault Code A153: Battery voltage is low with truck in operation............................................................... 464 Related circuit diagram................................................................................................... 465 Fault Code A154: Battery charging voltage is excessive........................................................................ 466 Related circuit diagram................................................................................................... 467 Fault Code A155: Battery charging voltage is low.............................................................................. 468 Related circuit diagram................................................................................................... 469 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 470 Related circuit diagram................................................................................................... 471 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 472 Related circuit diagram................................................................................................... 473 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 474 Related circuit diagram................................................................................................... 475 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 476 Related circuit diagram................................................................................................... 477 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 478 Related circuit diagram................................................................................................... 479 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 480 Related circuit diagram................................................................................................... 480 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 481 Related circuit diagram................................................................................................... 481 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 482 Related circuit diagram................................................................................................... 482 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 483 Related circuit diagram................................................................................................... 483 Fault Code A184: J1939 data link is not connected............................................................................. 484 Related circuit diagram................................................................................................... 485 Fault Code A190: Auto lube control has detected an incomplete lube cycle...................................................... 486 Related circuit diagram................................................................................................... 487 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 488 Related circuit diagram................................................................................................... 489 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 490 Related circuit diagram....................................................................................................... 491 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 492 Related circuit diagram....................................................................................................... 493 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 494 Related circuit diagram....................................................................................................... 495 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 496 Related circuit diagram................................................................................................... 496 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 497 Related circuit diagram................................................................................................... 497 Fault Code A200: Steering pressure sensor is high............................................................................. 498 Related circuit diagram................................................................................................... 498 Fault Code A201: Brake pressure sensor is high................................................................................ 499 Related circuit diagram................................................................................................... 499 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 500 Related circuit diagram................................................................................................... 500 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 501 Related circuit diagram................................................................................................... 501 Fault Code A204: Steering pressure sensor is low.............................................................................. 502 Related circuit diagram................................................................................................... 502 Fault Code A205: Brake pressure sensor is low................................................................................. 503 Related circuit diagram................................................................................................... 503 Fault Code A206: Ambient temperature sensor is high........................................................................... 504 Related circuit diagram................................................................................................... 504 Fault Code A207: Ambient temperature sensor is low............................................................................ 505 Related circuit diagram................................................................................................... 505 Fault Code A212: Bad truck speed signal....................................................................................... 506 Related circuit diagram................................................................................................... 507 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 508 Related circuit diagram................................................................................................... 510 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 512 Related circuit diagram................................................................................................... 514 Fault Code A215: Brake auto apply relay circuit is defective.................................................................. 516 Related circuit diagram................................................................................................... 517 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 518 Related circuit diagram................................................................................................... 519 SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292)................................................................................ 521 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 522 Related circuit diagram................................................................................................... 523 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 524 Related circuit diagram................................................................................................... 525 Fault Code A236: Steering accumulator has not properly bled down after 90 seconds............................................. 526 Related circuit diagram................................................................................................... 527 Fault Code A240: The keyswitch input to the interface module is open.......................................................... 528 Related circuit diagram................................................................................................... 529 Fault Code A246: Payload meter reports truck overload......................................................................... 529 Related circuit diagram................................................................................................... 529 Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted............................... 530 Related circuit diagram................................................................................................... 531 Fault Code A250: Battery voltage is low with the truck parked................................................................. 532 Related circuit diagram................................................................................................... 533 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 534 Related circuit diagram................................................................................................... 535 Fault Code A253: Steering bleed circuit is not open while running............................................................. 536 Related circuit diagram................................................................................................... 537 Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open.................................. 538 Related circuit diagram................................................................................................... 539 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 540 Related circuit diagram................................................................................................... 540 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 542 Related circuit diagram................................................................................................... 543 Fault Code A260: Parking brake failure........................................................................................ 544 Related circuit diagram................................................................................................... 545 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 546 Related circuit diagram................................................................................................... 547 Fault Code A263: Steering bleed circuit is shorted to ground.................................................................. 548 Related circuit diagram................................................................................................... 549 Fault Code A264: Parking brake relay circuit is defective..................................................................... 550 Related circuit diagram................................................................................................... 551 Fault Code A265: Service brake failure........................................................................................ 552 Related circuit diagram................................................................................................... 554 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 556 Related circuit diagram................................................................................................... 557 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 558 Related circuit diagram................................................................................................... 560 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 562 Related circuit diagram................................................................................................... 563 Fault Code A274: A brake setting fault has been detected...................................................................... 564 Related circuit diagram................................................................................................... 565 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 566 Related circuit diagram................................................................................................... 567 Fault Code A276: The drive system data link is not connected.................................................................. 568 Related circuit diagram................................................................................................... 569 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 570 Related circuit diagram................................................................................................... 571 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................... 572 Related circuit diagram................................................................................................... 573 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated...................... 574 Related circuit diagram................................................................................................... 575 Fault Code A285: The parking brake was not set when the key switch was turned off............................................. 576 Related circuit diagram................................................................................................... 577 Fault Code A286: A fault was detected in the shutdown delay relay circuit..................................................... 578 Related circuit diagram................................................................................................... 579 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off......................... 580 Related circuit diagram................................................................................................... 581 SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365)................................................................................ 583 Fault Code A303: Shifter is defective......................................................................................... 584 Related circuit diagram................................................................................................... 585 Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be............ 586 Related circuit diagram................................................................................................... 587 Fault Code A309: No brakes applied when expected.............................................................................. 588 Related circuit diagram................................................................................................... 590 Fault Code A311: Brake lock switch is on when it should not be................................................................ 592 Related circuit diagram................................................................................................... 593 Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings............................................ 594 Related circuit diagram................................................................................................... 594 Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings........................................... 595 Related circuit diagram................................................................................................... 595 Fault Code A315: DC-DC converter 12 volt circuit is low....................................................................... 596 Related circuit diagram................................................................................................... 597 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 598 Related circuit diagram................................................................................................... 599 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 600 Related circuit diagram................................................................................................... 602 Fault Code A318: Unexpected power loss to interface module.................................................................... 603 Related circuit diagram................................................................................................... 603 Fault Code A328: Drive system not powered up.................................................................................. 604 Related circuit diagram................................................................................................... 605 Fault Code A350: Overload on output 1B........................................................................................ 606 Related circuit diagram................................................................................................... 607 Fault Code A351: Overload on output 1E........................................................................................ 608 Related circuit diagram................................................................................................... 609 Fault Code A352: Overload on output 1H........................................................................................ 610 Related circuit diagram................................................................................................... 611 Fault Code A353: Overload on output 1J........................................................................................ 612 Related circuit diagram................................................................................................... 613 Fault Code A354: Overload on output 1K........................................................................................ 614 Related circuit diagram................................................................................................... 615 Fault Code A355: Overload on output 1L........................................................................................ 616 Related circuit diagram................................................................................................... 617 Fault Code A356: Overload on output 1M........................................................................................ 618 Related circuit diagram................................................................................................... 619 Fault Code A357: Overload on output 1N........................................................................................ 620 Related circuit diagram................................................................................................... 621 Fault Code A358: Overload on output 1P........................................................................................ 622 Related circuit diagram................................................................................................... 623 Fault Code A359: Overload on output 1R........................................................................................ 624 Related circuit diagram................................................................................................... 625 Fault Code A360: Overload on output 1S........................................................................................ 626 Related circuit diagram................................................................................................... 627 Fault Code A361: Overload on output 1T........................................................................................ 628 Related circuit diagram................................................................................................... 629 Fault Code A362: Overload on output 1U........................................................................................ 630 Related circuit diagram................................................................................................... 631 Fault Code A363: Overload on output 1X........................................................................................ 632 Related circuit diagram................................................................................................... 632 Fault Code A364: Overload on output 1Y........................................................................................ 634 Related circuit diagram................................................................................................... 635 Fault Code A365: Overload on output 1Z........................................................................................ 636 Related circuit diagram................................................................................................... 637 SECTION G REAR AXLE, SPINDLES AND WHEELS.............................................................................................. 639 SECTION G2 TIRES AND RIMS......................................................................................................... 641 TIRES AND RIMS................................................................................................................ 643 WHEEL STUD MAINTENANCE.................................................................................................... 644 FRONT TIRES AND RIMS...................................................................................................... 645 Removal............................................................................................................... 645 Installation.......................................................................................................... 646 REAR TIRES AND RIMS....................................................................................................... 647 Removal............................................................................................................... 647 Installation.......................................................................................................... 648 RIM....................................................................................................................... 649 Tire Removal.......................................................................................................... 649 Tire Installation..................................................................................................... 649 SECTION G3 FRONT WHEEL HUB AND SPINDLE............................................................................................ 651 FRONT WHEEL HUB AND SPINDLE................................................................................................... 653 WHEEL HUB AND SPINDLE ASSEMBLY............................................................................................ 653 Removal............................................................................................................... 653 Spindle Removal Procedure (off of the truck).......................................................................... 656 Installation.......................................................................................................... 658 Disassembly........................................................................................................... 659 Cleaning and Inspection............................................................................................... 661 Assembly.............................................................................................................. 661 Wheel Bearing Adjustment.............................................................................................. 662 Brake Installation.................................................................................................... 663 Seal Assembly Gap Check............................................................................................... 664 WHEEL SPEED SENSOR TESTING................................................................................................ 665 STEERING CYLINDERS........................................................................................................ 666 Spherical Bearing Wear Limits......................................................................................... 666 Removal............................................................................................................... 667 Installation.......................................................................................................... 667 Bearing Replacement (Steering Cylinder and Tie Rod)................................................................... 667 TIE ROD................................................................................................................... 669 Removal............................................................................................................... 669 Installation.......................................................................................................... 669 Disassembly........................................................................................................... 670 Assembly.............................................................................................................. 670 Toe-In Adjustment..................................................................................................... 671 TIE ROD INSPECTION AND TORQUE PROCEDURE................................................................................... 672 Old Style Tie Rod..................................................................................................... 672 New Style Tie Rod..................................................................................................... 673 SECTION G4 REAR AXLE MOUNTING..................................................................................................... 675 REAR AXLE MOUNTING............................................................................................................ 677 PIVOT PIN................................................................................................................. 677 Removal............................................................................................................... 677 Installation.......................................................................................................... 678 PIVOT EYE BEARING......................................................................................................... 678 Removal............................................................................................................... 678 Installation.......................................................................................................... 678 PIVOT EYE REPAIR.......................................................................................................... 679 Removal............................................................................................................... 679 Installation.......................................................................................................... 679 ANTI-SWAY BAR............................................................................................................. 680 Removal............................................................................................................... 680 Disassembly........................................................................................................... 680 Cleaning and Inspection............................................................................................... 680 Assembly.............................................................................................................. 680 Installation.......................................................................................................... 680 SECTION G5 REAR AXLE AND WHEEL MOTOR.............................................................................................. 683 REAR AXLE AND WHEEL MOTOR..................................................................................................... 685 REAR AXLE HOUSING......................................................................................................... 685 Preparation........................................................................................................... 685 Removal............................................................................................................... 686 Cleaning and Inspection............................................................................................... 687 Installation.......................................................................................................... 687 BLOWER PRESSURE SWITCH ADJUSTMENT......................................................................................... 687 WHEEL MOTOR............................................................................................................... 688 Preparation........................................................................................................... 688 Removal............................................................................................................... 689 Cleaning and Inspection............................................................................................... 691 Installation.......................................................................................................... 691 WHEEL MOTOR GEAR OIL...................................................................................................... 696 Filtering Requirements................................................................................................ 696 Particle Size Analysis................................................................................................ 696 Flushing.............................................................................................................. 696 Oil Sample Analysis................................................................................................... 697 ELEMENT SPECIFICATION CHARTS.............................................................................................. 698 SECTION H HYDRAIR® II SUSPENSIONS..................................................................................................... 701 SECTION H2 FRONT SUSPENSIONS...................................................................................................... 703 FRONT SUSPENSION.............................................................................................................. 705 Removal................................................................................................................... 705 Installation.............................................................................................................. 706 Inspection................................................................................................................ 711 LOWER BEARING & SEALS..................................................................................................... 712 Removal............................................................................................................... 712 Installation.......................................................................................................... 712 MAJOR SUSPENSION REBUILD.................................................................................................. 713 Disassembly........................................................................................................... 713 Assembly.............................................................................................................. 714 SUSPENSION PRESSURE TEST.................................................................................................. 715 SECTION H3 REAR SUSPENSIONS....................................................................................................... 717 REAR SUSPENSIONS.............................................................................................................. 719 SUSPENSION CYLINDER....................................................................................................... 720 Removal............................................................................................................... 720 Installation.......................................................................................................... 722 Disassembly........................................................................................................... 722 Cleaning and Inspection............................................................................................... 723 Assembly.............................................................................................................. 723 SUSPENSION PRESSURE TEST.................................................................................................. 725 SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES.............................................................................. 727 SUSPENSION OILING AND CHARGING PROCEDURE...................................................................................... 729 GENERAL................................................................................................................... 729 EQUIPMENT LIST............................................................................................................ 729 HYDRAIR® CHARGING KIT..................................................................................................... 730 Installation of Charging Kit.......................................................................................... 730 Removal of Charging Kit............................................................................................... 730 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS......................................................................... 731 FRONT SUSPENSION.......................................................................................................... 731 Front Suspension Oiling............................................................................................... 731 Front Suspension Nitrogen Charging.................................................................................... 733 REAR SUSPENSION........................................................................................................... 734 Rear Suspension Oiling................................................................................................ 735 Rear Suspension Nitrogen Charging..................................................................................... 737 OIL AND NITROGEN SPECIFICATIONS CHARTS........................................................................................ 738 SECTION J BRAKE CIRCUIT............................................................................................................... 739 SECTION J2 BRAKE CIRCUIT.......................................................................................................... 741 BRAKE CIRCUIT................................................................................................................. 743 SERVICE BRAKE CIRCUIT..................................................................................................... 743 PARKING BRAKE CIRCUIT..................................................................................................... 745 BRAKE LOCK CIRCUIT........................................................................................................ 745 SECONDARY BRAKING AND AUTOMATIC APPLY..................................................................................... 746 WARNING CIRCUIT........................................................................................................... 746 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE........................................................................................ 749 BRAKE CIRCUIT COMPONENT SERVICE............................................................................................... 751 BRAKE VALVE............................................................................................................... 751 Rebuild Criteria...................................................................................................... 751 Removal............................................................................................................... 752 Installation.......................................................................................................... 752 Disassembly........................................................................................................... 753 Cleaning and Inspection............................................................................................... 756 Assembly.............................................................................................................. 756 Regulator Sleeve O-Ring Installation.................................................................................. 757 BRAKE VALVE BENCH TEST AND ADJUSTMENT..................................................................................... 759 Test Setup Procedure.................................................................................................. 760 Brake Valve Output Pressure Adjustment................................................................................ 760 Final Test and Adjustment............................................................................................. 761 Installing Brake Pedal Actuator Assembly to Brake Valve............................................................... 761 Installing Retard Pedal To Brake Pedal................................................................................ 761 DUAL RELAY VALVE.......................................................................................................... 762 Removal............................................................................................................... 762 Installation.......................................................................................................... 762 Disassembly........................................................................................................... 762 Cleaning and Inspection............................................................................................... 763 Assembly.............................................................................................................. 764 DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT................................................................................ 765 Test Setup Procedure.................................................................................................. 766 Relay Valve Output Pressure Adjustment................................................................................ 766 BRAKE MANIFOLD............................................................................................................ 767 Removal............................................................................................................... 767 Installation.......................................................................................................... 767 Disassembly........................................................................................................... 767 Cleaning and Inspection............................................................................................... 768 Assembly.............................................................................................................. 768 BRAKE ACCUMULATORS........................................................................................................ 768 Brake Accumulator Bleeddown Procedure................................................................................. 768 Removal............................................................................................................... 769 Installation.......................................................................................................... 769 Disassembly........................................................................................................... 770 Cleaning and Inspection............................................................................................... 771 Assembly.............................................................................................................. 771 Accumulator Charging Procedure........................................................................................ 773 Precharge Maintenance................................................................................................. 775 Accumulator Storage Procedures........................................................................................ 776 Bladder Storage Procedures............................................................................................ 776 Installing A Bladder Accumulator From Storage......................................................................... 776 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................................................... 777 Removal............................................................................................................... 777 Installation.......................................................................................................... 777 Disassembly........................................................................................................... 777 Lever Adjustments..................................................................................................... 777 Potentiometer Check................................................................................................... 778 Assembly.............................................................................................................. 778 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE...................................................................................... 781 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................................................. 783 REQUIRED EQUIPMENT........................................................................................................ 784 INITIAL SYSTEM SETUP...................................................................................................... 785 BRAKE LOCK / SECONDARY BRAKE CHECK-OUT.................................................................................... 786 PARKING BRAKE CHECK-OUT................................................................................................... 787 SERVICE BRAKE CHECK-OUT................................................................................................... 788 LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT......................................................................... 789 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART........................................................................... 790 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET......................................................................... 792 SECTION J5 WET DISC BRAKE ASSEMBLY................................................................................................ 795 WET DISC BRAKE ASSEMBLY....................................................................................................... 797 OPERATION................................................................................................................. 797 BRAKE DISC WEAR INSPECTION................................................................................................ 798 BRAKE REBUILD............................................................................................................. 799 Disassembly........................................................................................................... 799 Cleaning and Inspection............................................................................................... 803 Assembly.............................................................................................................. 804 Floating Ring Seal Assembly & Installation............................................................................ 809 WET DISC BRAKE BLEEDING PROCEDURE......................................................................................... 813 SECTION J7 PARKING BRAKE.......................................................................................................... 815 PARKING BRAKE................................................................................................................. 817 OPERATION................................................................................................................. 817 MAINTENANCE............................................................................................................... 818 Inspection............................................................................................................ 818 Removal............................................................................................................... 818 Installation.......................................................................................................... 819 Disassembly........................................................................................................... 819 Cleaning and Inspection............................................................................................... 819 Assembly.............................................................................................................. 821 Cleaning and Inspecting New Discs..................................................................................... 822 PARKING BRAKE BLEEDING PROCEDURE.......................................................................................... 823 SECTION L HYDRAULIC SYSTEM............................................................................................................ 825 SECTION L2 HYDRAULIC SYSTEM....................................................................................................... 827 HYDRAULIC SYSTEM.............................................................................................................. 829 HYDRAULIC PUMP MODULE..................................................................................................... 829 HOIST CIRCUIT OPERATION................................................................................................... 830 STEERING CIRCUIT OPERATION................................................................................................ 832 DISC BRAKE COOLING SYSTEM................................................................................................. 834 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR...................................................................................... 837 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................................................. 839 HOIST PUMP................................................................................................................ 839 Removal............................................................................................................... 839 Installation.......................................................................................................... 841 Inspection............................................................................................................ 846 Assembly.............................................................................................................. 846 HYDRAULIC TANK............................................................................................................ 852 Removal............................................................................................................... 852 Installation.......................................................................................................... 853 HYDRAULIC TANK BREATHERS.................................................................................................. 854 HYDRAULIC TANK STRAINERS.................................................................................................. 854 Removal............................................................................................................... 854 Inspect and Clean..................................................................................................... 854 Installation.......................................................................................................... 854 SECTION L4 STEERING CIRCUIT....................................................................................................... 855 STEERING CIRCUIT.............................................................................................................. 857 STEERING CIRCUIT OPERATION................................................................................................ 857 COMPONENT DESCRIPTION..................................................................................................... 858 Steering Control Unit................................................................................................. 858 Bleeddown Manifold.................................................................................................... 859 Steering Accumulator Bleed Down Solenoid.............................................................................. 859 Relief Valves......................................................................................................... 861 Hoist Up Limit Solenoid............................................................................................... 861 Steering Accumulators................................................................................................. 861 Low Precharge Warning Switch.......................................................................................... 861 High Pressure Filter.................................................................................................. 861 Quick Disconnect Ports................................................................................................ 861 Flow Amplifier........................................................................................................ 863 FLOW AMPLIFIER SYSTEM OPERATION........................................................................................... 864 No Steer.............................................................................................................. 864 Steering Left......................................................................................................... 866 Steering Right........................................................................................................ 868 No Steer, External Shock Load......................................................................................... 870 STEERING PUMP............................................................................................................. 872 Normal Operation...................................................................................................... 872 PRINCIPLE OF OPERATION.................................................................................................... 874 Full Pump Volume...................................................................................................... 874 Half Pump Volume...................................................................................................... 874 Neutral Position...................................................................................................... 874 Steering Pump......................................................................................................... 875 SECTION L5 STEERING CONTROL UNIT.................................................................................................. 877 STEERING CONTROL UNIT......................................................................................................... 879 REMOVAL................................................................................................................... 879 SPLINE INSPECTION......................................................................................................... 879 INSTALLATION.............................................................................................................. 880 DISASSEMBLY............................................................................................................... 880 CLEANING AND INSPECTION................................................................................................... 881 ASSEMBLY.................................................................................................................. 883 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR...................................................................................... 887 STEERING CIRCUIT COMPONENT REPAIR............................................................................................. 889 BLEEDDOWN MANIFOLD VALVE.................................................................................................. 889 Removal............................................................................................................... 889 Installation.......................................................................................................... 890 FLOW AMPLIFIER............................................................................................................ 891 Removal............................................................................................................... 891 Installation.......................................................................................................... 891 Disassembly........................................................................................................... 891 Assembly.............................................................................................................. 893 STEERING CYLINDERS........................................................................................................ 894 Disassembly........................................................................................................... 895 Piston Seal & Bearing Installation.................................................................................... 895 Assembly.............................................................................................................. 895 Testing............................................................................................................... 895 STEERING AND BRAKE PUMP................................................................................................... 896 Removal............................................................................................................... 896 Installation.......................................................................................................... 897 Disassembly........................................................................................................... 898 Inspection............................................................................................................ 901 Assembly.............................................................................................................. 904 Driveshaft Group...................................................................................................... 905 Rotating Group........................................................................................................ 905 Valve Plate Group..................................................................................................... 906 STEERING ACCUMULATORS..................................................................................................... 908 Removal............................................................................................................... 908 Installation.......................................................................................................... 908 Disassembly........................................................................................................... 909 Cleaning and Inspection............................................................................................... 909 Assembly.............................................................................................................. 910 Leak Testing.......................................................................................................... 912 Charging Procedure.................................................................................................... 913 Precharge Maintenance................................................................................................. 915 Accumulator Storage Procedures........................................................................................ 916 Bladder Storage Procedures............................................................................................ 916 Installing A Bladder Accumulator From Storage......................................................................... 916 TROUBLESHOOTING CHART......................................................................................................... 917 SECTION L7 HOIST CIRCUIT.......................................................................................................... 921 HOIST CIRCUIT................................................................................................................. 923 BASIC OPERATION........................................................................................................... 923 COMPONENT DESCRIPTION..................................................................................................... 924 Hydraulic Tank........................................................................................................ 924 Hydraulic Pump........................................................................................................ 924 High Pressure Filters................................................................................................. 924 Hoist Valve........................................................................................................... 924 Inlet Sections........................................................................................................ 924 Work Ports (Rear) Spool Section....................................................................................... 925 Tank Ports (Front) Spool Section...................................................................................... 925 Hoist Pilot Valve..................................................................................................... 925 Bleeddown Manifold.................................................................................................... 926 Hoist Up Limit Solenoid............................................................................................... 926 Pilot Operated Check Valve............................................................................................ 926 Overcenter Manifold................................................................................................... 926 HOIST CIRCUIT OPERATION....................................................................................................... 927 Float Position Of Pilot Valve With Truck Body On Frame.................................................................... 928 Power Up Operation........................................................................................................ 930 Hold Operation............................................................................................................ 932 Power Down Operation...................................................................................................... 934 Float Operation........................................................................................................... 936 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR......................................................................................... 939 HOIST CIRCUIT COMPONENT REPAIR................................................................................................ 941 HOIST VALVE............................................................................................................... 941 Removal............................................................................................................... 941 Installation.......................................................................................................... 942 O-Ring Replacement.................................................................................................... 942 INLET SECTION............................................................................................................. 943 Disassembly........................................................................................................... 943 Cleaning and Inspection............................................................................................... 944 Assembly.............................................................................................................. 944 REAR SPOOL SECTION (Work Ports)........................................................................................... 945 Disassembly........................................................................................................... 945 Cleaning and Inspection............................................................................................... 945 Assembly.............................................................................................................. 947 FRONT SPOOL SECTION (Tank Ports).......................................................................................... 948 Disassembly........................................................................................................... 948 Cleaning and Inspection............................................................................................... 948 Assembly.............................................................................................................. 948 HOIST PILOT VALVE......................................................................................................... 950 Removal............................................................................................................... 950 Installation.......................................................................................................... 950 Disassembly........................................................................................................... 951 Cleaning and Inspection............................................................................................... 952 Assembly.............................................................................................................. 952 HOIST CYLINDERS........................................................................................................... 953 Removal............................................................................................................... 953 Installation.......................................................................................................... 954 Disassembly........................................................................................................... 956 Cleaning and Inspection............................................................................................... 957 Assembly - Quill...................................................................................................... 958 Assembly - Cylinder................................................................................................... 960 Testing............................................................................................................... 960 OVERCENTER VALVE MANIFOLD................................................................................................. 961 SECTION L9 HYDRAULIC SYSTEM FILTERS............................................................................................... 963 HYDRAULIC SYSTEM FILTERS...................................................................................................... 965 HOIST CIRCUIT FILTER...................................................................................................... 965 Filter Element Replacement............................................................................................ 965 Removal - Hoist Circuit Filter........................................................................................ 966 Installation - Hoist Circuit Filter................................................................................... 966 Indicator Switch - Hoist Circuit Filter............................................................................... 966 STEERING CIRCUIT FILTER................................................................................................... 967 Filter Element Replacement............................................................................................ 967 Removal - Steering Circuit Filter..................................................................................... 968 Installation - Steering Circuit Filter................................................................................ 968 Indicator Switch - Steering Circuit Filter............................................................................ 968 INDICATOR SWITCH.......................................................................................................... 968 Test Procedure........................................................................................................ 968 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE.......................................................................................... 971 HYDRAULIC CHECKOUT PROCEDURE.................................................................................................. 973 GENERAL INFORMATION....................................................................................................... 973 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................................................... 980 Equipment Requirements................................................................................................ 981 Pump Pressure Control Adjustments..................................................................................... 981 Steering Control Valve and Flow Amplifier Leakage Test................................................................ 982 Bleeddown Manifold Leakage Test....................................................................................... 983 STEERING/BRAKE PUMP STROKE ADJUSTMENT..................................................................................... 984 SHOCK AND SUCTION VALVES.................................................................................................. 984 Equipment Requirements................................................................................................ 984 Pressure Tests........................................................................................................ 984 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES............................................................. 986 Equipment Requirements................................................................................................ 986 Pressure Gauge Locations.............................................................................................. 986 Brake Cooling Circuit Test............................................................................................ 986 Power Up Relief Pressure Test......................................................................................... 987 Power Down Relief Pressure Test....................................................................................... 988 Counterbalance Valve Pressure Check................................................................................... 989 Counterbalance Valve Adjustment....................................................................................... 990 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET......................................................................... 991 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET............................................................ 992 SECTION M OPTIONS AND SPECIAL TOOLS................................................................................................... 993 SECTION M7 HOT START SYSTEM....................................................................................................... 995 HOT START SYSTEM.............................................................................................................. 997 SYSTEM OPERATION.......................................................................................................... 997 HEATER INFORMATION........................................................................................................ 998 TROUBLESHOOTING GUIDELINES................................................................................................ 999 SECTION M8 SPECIAL TOOLS..........................................................................................................1001 HIGH VOLTAGE TOOLS............................................................................................................1006 0-2000 VDC CUSTOM METER KIT (58B-06-00800)....................................................................................1006 SECTION M19 RADIATOR SHUTTERS.....................................................................................................1009 RADIATOR SHUTTERS.............................................................................................................1011 OPERATION.................................................................................................................1011 Hydraulic Circuit.....................................................................................................1011 Electrical Circuit....................................................................................................1012 MAINTENANCE AND REPAIR....................................................................................................1012 TROUBLESHOOTING...........................................................................................................1013 SECTION M20 PAYLOAD METER III ™...................................................................................................1017 OPERATION SECTION.............................................................................................................1021 Introduction..............................................................................................................1021 Data Summary..........................................................................................................1021 Data Gathering........................................................................................................1021 COMPONENT DESCRIPTION.....................................................................................................1022 System Diagram........................................................................................................1022 Suspension Pressure Sensors...........................................................................................1022 Inclinometer..........................................................................................................1022 Operator Display......................................................................................................1022 Operator Switch.......................................................................................................1023 Speed Input...........................................................................................................1023 Body-Up Switch........................................................................................................1023 Brake Lock Switch.....................................................................................................1023 Payload Meter.........................................................................................................1023 Communications Ports..................................................................................................1023 Key Switch Input......................................................................................................1024 Payload Meter Power...................................................................................................1024 Load Lights...........................................................................................................1024 Wiring and Termination................................................................................................1025 TCI Outputs...........................................................................................................1025 OPERATOR’S DISPLAY AND SWITCH.............................................................................................1026 Reading the Speedometer...............................................................................................1026 Reading the Load Display..............................................................................................1026 Using the Operator ID.................................................................................................1026 Using the Load and Ton Counter........................................................................................1026 Total Ton Counter.....................................................................................................1026 Total Load Counter....................................................................................................1027 Clearing the Counters.................................................................................................1027 Viewing Live Sensor Data..............................................................................................1027 Other Display Messages................................................................................................1027 PAYLOAD OPERATION & CALCULATION...........................................................................................1028 Description of Haul Cycle States......................................................................................1028 Haul Cycle Description................................................................................................1028 Load Calculation......................................................................................................1029 Carry Back............................................................................................................1029 Measurement Accuracy..................................................................................................1029 SOURCES FOR PAYLOAD ERROR.................................................................................................1029 Payload Error.........................................................................................................1029 Loading Conditions....................................................................................................1030 Pressure Sensors......................................................................................................1030 Swingloads............................................................................................................1030 Speed and Distance....................................................................................................1030 HAUL CYCLE DATA...........................................................................................................1030 Haul Cycle Warning Flags..............................................................................................1032 Frame Torque Data.....................................................................................................1033 Sprung Weight Data....................................................................................................1033 Maximum Speed Data....................................................................................................1033 Alarm Records.........................................................................................................1033 Fault Code Data.......................................................................................................1034 PC SOFTWARE OVERVIEW......................................................................................................1035 System Configuration..................................................................................................1035 Installing the PLMIII Software........................................................................................1035 DOWNLOADING DATA..........................................................................................................1036 PLM III SYSTEM CONFIGURATION..............................................................................................1037 Starting Communications...............................................................................................1037 Displayed Payload Units...............................................................................................1037 Time Units............................................................................................................1037 Connection Menu.......................................................................................................1037 Connecting to the Payload Meter.......................................................................................1038 Configure the Payload Meter...........................................................................................1038 Setting the Date and Time.............................................................................................1038 Setting the Truck Type................................................................................................1039 Setting the Gauge Display Units.......................................................................................1039 Setting the Frame Serial Number.......................................................................................1039 Setting the Truck Number..............................................................................................1039 Setting the Komatsu Distributor.......................................................................................1039 Setting the Komatsu Customer..........................................................................................1039 Clean Truck Tare Calibration..........................................................................................1040 Inclinometer Calibration..............................................................................................1040 DATA ANALYSIS.............................................................................................................1041 Creating a Query......................................................................................................1041 Sorting on Truck Unit Number..........................................................................................1041 Sorting on Truck Type.................................................................................................1041 Sorting on Date Range.................................................................................................1042 Sorting on Time Range.................................................................................................1042 Payload Detail Screen.................................................................................................1043 Creating Reports......................................................................................................1043 Summary - one page report.............................................................................................1044 Detailed - multi-page report..........................................................................................1044 Creating Graphs.......................................................................................................1045 Exporting Data........................................................................................................1045 CSV Export............................................................................................................1045 Compressed............................................................................................................1046 Importing Data........................................................................................................1047 Deleting Haul Cycle Records...........................................................................................1047 Viewing Alarms........................................................................................................1048 Deleting Alarm Records................................................................................................1048 TROUBLESHOOTING SECTION.......................................................................................................1049 TROUBLESHOOTING...........................................................................................................1049 Viewing Active Alarms.................................................................................................1049 Real-Time Data Display................................................................................................1049 Testing the Payload Lights............................................................................................1049 Creating Log Files of Inputs..........................................................................................1050 Daily Inspections.....................................................................................................1050 Periodic Maintenance..................................................................................................1050 Abnormal Displays at Power-Up.........................................................................................1051 No Payload Display When Key Switch is Turned ON.......................................................................1052 No Display on Speedometer.............................................................................................1053 No Display on Operator Display........................................................................................1053 No Communications With PC.............................................................................................1054 Load Lights Don’t Light During Loading................................................................................1055 Load Lights Remain ON.................................................................................................1056 Load Lights Remain ON During Dumping..................................................................................1056 Display Doesn't Clear When The Load Is Dumped.........................................................................1056 Calibration Problems..................................................................................................1057 Alarm 1 - Left Front Pressure High....................................................................................1058 Alarm 2 - Left Front Pressure Low.....................................................................................1058 Troubleshoot Wiring to Left Front Suspension..........................................................................1058 Alarm 3 - Right Front Pressure High...................................................................................1059 Alarm 4 - Right Front Pressure Low....................................................................................1059 Troubleshoot Wiring to Right Front Suspension.........................................................................1059 Alarm 5 -Left Rear Pressure High......................................................................................1060 Alarm 6 - Left Rear Pressure Low......................................................................................1060 Troubleshoot Wiring to Left Rear Suspension...........................................................................1060 Alarm 7 - Right Rear Pressure High....................................................................................1061 Alarm 8 - Right Rear Pressure Low.....................................................................................1061 Troubleshoot Wiring to Right Rear Suspension..........................................................................1061 Alarm 9 - Inclinometer High...........................................................................................1062 Alarm 10 - Inclinometer Low...........................................................................................1062 Troubleshoot Inclinometer Wiring......................................................................................1062 Alarm 13 - Body Up Input Failure......................................................................................1063 Alarm 16 - Memory Write Failure.......................................................................................1064 Alarm 17 - Memory Read Failure........................................................................................1064 Alarm 18..............................................................................................................1065 Alarm 19..............................................................................................................1065 Alarm 22..............................................................................................................1065 Operator Switch Doesn't Work..........................................................................................1066 Alarm 26 - User Switch Fault - SELECT.................................................................................1066 Alarm 27 - User Switch Fault - SET....................................................................................1066 Connector Map.........................................................................................................1067 Connectors............................................................................................................1068 PLMIII CHECK OUT PROCEDURE....................................................................................................1069 General Description.......................................................................................................1069 Tools Required............................................................................................................1069 Checkout Procedure........................................................................................................1069 PLMIII CHECKOUT PROCEDURE CONFIRMATION....................................................................................1073 Flashburn Programming.................................................................................................1073 Confirmation Checklist................................................................................................1075 SECTION M31 RESERVE ENGINE OIL SYSTEM.............................................................................................1077 RESERVE ENGINE OIL SYSTEM.....................................................................................................1079 Operation.................................................................................................................1080 LED Monitor Light.........................................................................................................1080 Tank Fill Control (Optional)..............................................................................................1081 Filling Procedure (Remote Fill Feature)...................................................................................1081 SERVICE...................................................................................................................1082 Every 10 Hours, or once each shift:...................................................................................1082 Every 500 Hours.......................................................................................................1082 Changing Oil..........................................................................................................1082 TROUBLESHOOTING...........................................................................................................1083 Circuit Fuse..........................................................................................................1083 SYSTEM ELECTRICAL SCHEMATICS..............................................................................................1084 SECTION N OPERATOR CAB................................................................................................................1085 SECTION N2 TRUCK CAB AND COMPONENTS...............................................................................................1087 TRUCK CAB AND COMPONENTS......................................................................................................1089 TRUCK CAB.................................................................................................................1089 Description...........................................................................................................1089 Removal...............................................................................................................1090 Installation..........................................................................................................1091 CAB DOOR..................................................................................................................1092 Removal...............................................................................................................1092 Installation..........................................................................................................1092 Door Jamb Bolt Adjustment.............................................................................................1093 Door Handle Plunger Adjustment........................................................................................1094 Replacing the Door Glass..............................................................................................1095 Replacing the Door Handle or Latch Assembly...........................................................................1099 Replacing the Door Window Regulator...................................................................................1100 Replacing the Door and Door Hinge Seal................................................................................1101 Replacing the Door Opening Seal.......................................................................................1101 GLASS REPLACEMENT (Adhesive-Bonded Windows)...............................................................................1102 Recommended Tools and Supplies........................................................................................1102 Replacement Procedure.................................................................................................1102 WINDSHIELD AND REAR GLASS.................................................................................................1103 Removal...............................................................................................................1103 Installation..........................................................................................................1104 SECTION N3 CAB COMPONENTS.........................................................................................................1105 CAB COMPONENTS................................................................................................................1107 WINDSHIELD WIPERS.........................................................................................................1107 WIPER MOTOR...........................................................................................................1107 Removal...........................................................................................................1107 Installation......................................................................................................1107 WIPER ARM.............................................................................................................1107 Removal...........................................................................................................1107 Installation......................................................................................................1108 WIPER LINKAGE.........................................................................................................1108 Removal...........................................................................................................1108 Installation......................................................................................................1108 WINDSHIELD WASHER.........................................................................................................1109 Operation.............................................................................................................1109 Service...............................................................................................................1109 OPERATOR SEAT.............................................................................................................1110 Adjustment............................................................................................................1110 Inspection............................................................................................................1111 Removal...............................................................................................................1111 Installation..........................................................................................................1111 PASSENGER SEAT............................................................................................................1112 Inspection............................................................................................................1112 Removal...............................................................................................................1112 Installation..........................................................................................................1112 SEAT BELT.................................................................................................................1113 Removal...............................................................................................................1113 Installation..........................................................................................................1113 SECTION N4 HEATER / AIR CONDITIONER...............................................................................................1115 HEATER/AIR CONDITIONER........................................................................................................1117 OPERATION.................................................................................................................1117 Fan Speed Control Knob................................................................................................1117 Temperature Control Knob..............................................................................................1117 Air Flow Directional Knob.............................................................................................1118 Heater/Air Conditioner Vents..........................................................................................1118 COMPONENTS................................................................................................................1118 Fuse and Circuit Breaker..............................................................................................1118 Relays................................................................................................................1118 Heater Core...........................................................................................................1119 Fan Motor And Speed Control...........................................................................................1119 Actuators.............................................................................................................1119 Cab Air Filter........................................................................................................1119 ENVIRONMENTAL IMPACT OF AIR CONDITIONING..................................................................................1122 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.................................................................................1122 PRINCIPLES OF REFRIGERATION...............................................................................................1122 Air Conditioning......................................................................................................1122 Refrigeration - The Act Of Cooling....................................................................................1123 The Refrigeration Cycle...............................................................................................1123 AIR CONDITIONER SYSTEM COMPONENTS.........................................................................................1124 Compressor (Refrigerant Pump).........................................................................................1124 Service Valves........................................................................................................1124 Condenser.............................................................................................................1124 Receiver-Drier........................................................................................................1124 Expansion Block Valve.................................................................................................1125 Accumulator...........................................................................................................1125 Evaporator............................................................................................................1125 ELECTRICAL CIRCUIT........................................................................................................1126 Thermostat............................................................................................................1126 Compressor Clutch.....................................................................................................1126 Trinary™ Switch.......................................................................................................1127 AIR CONDITIONING SYSTEM SERVICING WARNINGS................................................................................1128 SERVICE TOOLS AND EQUIPMENT...............................................................................................1129 Recovery/Recycle Station..............................................................................................1129 Leak Detector.........................................................................................................1129 Manifold Gauge Set....................................................................................................1130 Installing Manifold Gauge Set.........................................................................................1131 Purging Air From Service Hoses........................................................................................1131 Service Valves........................................................................................................1132 Vacuum Pump...........................................................................................................1132 SYSTEM PERFORMANCE TEST...................................................................................................1133 SYSTEM OIL................................................................................................................1134 Handling and Reusing PAG Oil..........................................................................................1134 Oil Quantity..........................................................................................................1134 Checking System Oil...................................................................................................1134 REFRIGERANT...............................................................................................................1135 Recycled Refrigerant..................................................................................................1135 Reclaimed Refrigerant.................................................................................................1135 Refrigerant Quantity..................................................................................................1136 R-134a Refrigerant Containers.........................................................................................1136 SYSTEM LEAK TESTING.......................................................................................................1136 Electronic Leak Detector..............................................................................................1137 Tracer Dyes...........................................................................................................1137 Soap and Water........................................................................................................1137 RECOVERING AND RECYCLING THE REFRIGERANT..................................................................................1137 Draining Oil from the Previous Recovery Cycle.........................................................................1137 Performing the Recovery Cycle.........................................................................................1137 Performing the Recycling Procedure....................................................................................1138 Evacuating and Charging the A/C System................................................................................1138 SYSTEM REPAIR.............................................................................................................1138 System Flushing.......................................................................................................1138 A/C DRIVE BELT CHECKOUT PROCEDURE.........................................................................................1139 Pulley Alignment......................................................................................................1139 Belt Tension Check....................................................................................................1139 COMPONENT REPLACEMENT.....................................................................................................1141 Hoses and Fittings....................................................................................................1141 Lines.................................................................................................................1141 Expansion Valve.......................................................................................................1141 Receiver-Drier........................................................................................................1141 Thermostat............................................................................................................1141 Compressor............................................................................................................1142 Accumulator...........................................................................................................1142 Clutch................................................................................................................1142 Servicing the Compressor Clutch.......................................................................................1143 Pulley Removal........................................................................................................1145 Clutch Coil Check.....................................................................................................1145 Pulley Installation...................................................................................................1145 Clutch Assembly Installation..........................................................................................1146 EVACUATING THE SYSTEM.....................................................................................................1147 CHARGING THE A/C SYSTEM...................................................................................................1148 TROUBLESHOOTING...........................................................................................................1149 Preliminary Checks....................................................................................................1149 Diagnosis Of Gauge Readings And System Performance....................................................................1149 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................................................................1150 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM................................................................................1156 SECTION N5 OPERATOR CAB CONTROLS..................................................................................................1157 OPERATOR CAB CONTROLS.........................................................................................................1160 STEERING COLUMN...........................................................................................................1161 Removal...............................................................................................................1161 Inspection............................................................................................................1161 Installation..........................................................................................................1162 STEERING WHEEL............................................................................................................1162 Removal...............................................................................................................1162 Installation..........................................................................................................1162 STEERING WHEEL AND CONTROLS...............................................................................................1164 Horn Button...........................................................................................................1164 Tilt / Telescope Lever................................................................................................1164 Multi-Function Turn Signal Switch.....................................................................................1164 DYNAMIC RETARDING.........................................................................................................1165 Retarder Lever........................................................................................................1165 Brake/Retarder Pedal..................................................................................................1165 Throttle/Accelerator Pedal............................................................................................1165 GRADE/SPEED CHART.........................................................................................................1166 OVERHEAD PANEL AND DISPLAYS...............................................................................................1167 Speakers..............................................................................................................1167 Warning Alarm Buzzer..................................................................................................1167 Radio/CD Player.......................................................................................................1167 Warning Indicator Light Dimmer Control................................................................................1167 Status/Warning Indicator Light Panel..................................................................................1167 Air Cleaner Restriction Gauges........................................................................................1167 CENTER CONSOLE............................................................................................................1168 Directional Control Lever.............................................................................................1168 Override/Fault Reset Switch...........................................................................................1169 Engine Shutdown Switch................................................................................................1169 Window Control Switches...............................................................................................1169 Hoist Control Lever...................................................................................................1169 Retarder Speed Control (RSC) Adjustment Dial..........................................................................1170 Retarder Speed Control (RSC) Switch...................................................................................1170 Data Store Button.....................................................................................................1171 KOMTRAX Plus Snapshot In Progress Light...............................................................................1171 Link Energized Light..................................................................................................1171 Service Engine Light..................................................................................................1171 12V Auxiliary Power Outlets...........................................................................................1171 DIAGNOSTIC PORTS..........................................................................................................1171 KOMTRAX Plus Diagnostic Port..........................................................................................1171 Interface Module (IM) Diagnostic Port.................................................................................1171 Payload Meter Diagnostic Port.........................................................................................1171 Truck Control Interface (TCI) Diagnostic Port.........................................................................1171 Propulsion System Controller (PSC) Diagnostic Port....................................................................1171 Engine Diagnostic Port (CENSE)........................................................................................1171 Engine Diagnostic Port (QUANTUM)......................................................................................1171 INSTRUMENT PANEL..........................................................................................................1172 Control Symbols.......................................................................................................1172 Key Switch............................................................................................................1174 Rotating Beacon Switch (optional).....................................................................................1174 Heated Mirrors Switch (optional)......................................................................................1174 AC Drive System Rest Switch...........................................................................................1174 Wheel Brake Lock Switch...............................................................................................1175 Hazard Warning Lights.................................................................................................1175 Heater/Air Conditioner Vents..........................................................................................1175 Engine Oil Pressure Gauge.............................................................................................1175 Right Turn Signal Indicator...........................................................................................1175 Digital Tachometer....................................................................................................1175 High Beam Indicator...................................................................................................1175 Speedometer/Payload Meter Display.....................................................................................1175 Left Turn Signal Indicator............................................................................................1176 Coolant Temperature Gauge.............................................................................................1176 Lamp Check Switch.....................................................................................................1176 Light Switch (3-Way)..................................................................................................1176 Ladder Light Switch...................................................................................................1176 Backup Light Switch...................................................................................................1176 Fog Light Switch......................................................................................................1176 Payload Meter Switch..................................................................................................1177 Panel Illumination Light Dimmer Switch................................................................................1177 Hydraulic Oil Temperature Gauge.......................................................................................1177 Engine Hourmeter......................................................................................................1177 Fuel Gauge............................................................................................................1177 OVERHEAD STATUS / WARNING INDICATORS......................................................................................1178 A1. High Hydraulic Oil Temperature....................................................................................1179 B1. Low Steering Pressure.............................................................................................1179 C1. Low Accumulator Precharge Pressure................................................................................1180 D1. Not used..........................................................................................................1180 E1. Low Brake Pressure................................................................................................1180 A2. Low Hydraulic Tank Level..........................................................................................1180 B2. Low Automatic Lubrication System Pressure.........................................................................1180 C2. Circuit Breaker Tripped...........................................................................................1180 D2. Hydraulic Oil Filter Monitor......................................................................................1181 E2. Low Fuel..........................................................................................................1181 A3. Parking Brake.....................................................................................................1181 B3. Service Brake.....................................................................................................1181 C3. Body Up...........................................................................................................1181 D3. Dynamic Retarding.................................................................................................1181 E3. Stop Engine.......................................................................................................1182 A4. Cranking Motor Failure............................................................................................1182 B4. Backup Lights.....................................................................................................1182 C4. Engine Shutdown Timer.............................................................................................1182 D4. Retard Speed Control (RSC) Indicator..............................................................................1182 E4. Check Engine......................................................................................................1182 A5. No Power..........................................................................................................1183 B5. Propulsion System Warning.........................................................................................1183 C5. Propulsion System Temperature.....................................................................................1183 D5. System/Component Failure..........................................................................................1183 E5. Battery Charging System Failure...................................................................................1183 A6. No Propel.........................................................................................................1183 B6. Propel System At Rest.............................................................................................1183 C6. Propel System Not Ready...........................................................................................1184 D6. Reduced Propulsion................................................................................................1184 E6. Retard At Continuous Level........................................................................................1184 REAR AXLE LIGHT BAR.......................................................................................................1185 Backup Lights.........................................................................................................1185 Retard Lights.........................................................................................................1185 Brake Light...........................................................................................................1185 Backup Alarm..........................................................................................................1185 KOMTRAX PLUS..............................................................................................................1186 Operation.............................................................................................................1186 Interface Module......................................................................................................1188 Basic Precautions.....................................................................................................1188 KOMATSU WIRELESS BRIDGE (Optional)........................................................................................1189 General Information...................................................................................................1189 Communication Setup...................................................................................................1189 Switching to the KWB_SETUP Network....................................................................................1189 Setting the Computer Subnet Mask and IP Address.......................................................................1190 Properties............................................................................................................1190 Setting Up the KWB....................................................................................................1191 Adding Encryption.....................................................................................................1191 Final Computer Settings...............................................................................................1191 Data Downloading......................................................................................................1192 Resetting the KWB.....................................................................................................1192 KWB Lights............................................................................................................1192 SECTION P LUBRICATION AND SERVICE.....................................................................................................1193 SECTION P2 LUBRICATION AND SERVICE................................................................................................1195 LUBRICATION AND SERVICE.......................................................................................................1197 GENERAL...................................................................................................................1197 SERVICE CAPACITIES........................................................................................................1197 HYDRAULIC TANK SERVICE....................................................................................................1197 Adding Oil............................................................................................................1197 COOLING SYSTEM SERVICE....................................................................................................1198 Radiator Filling Procedure............................................................................................1198 Coolant Specifications................................................................................................1198 Unacceptable Practices................................................................................................1198 WHEEL MOTOR SERVICE.......................................................................................................1198 RESERVE OIL TANK SERVICE..................................................................................................1199 Filling the Reserve Oil Tank (Remote Fill)............................................................................1199 Inline Screen.........................................................................................................1199 QUICK FILL SERVICE CENTER.................................................................................................1200 LUBRICATION CHART.........................................................................................................1201 10 HOUR (DAILY) INSPECTIONS...............................................................................................1202 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................1204 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1204 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1204 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1207 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................1209 5000 HOUR MAINTENANCE CHECKS..............................................................................................1209 SECTION P3 AUTOMATIC LUBRICATION SYSTEM...........................................................................................1211 AUTOMATIC LUBRICATION SYSTEM..................................................................................................1213 GENERAL DESCRIPTION.......................................................................................................1213 SYSTEM COMPONENTS.........................................................................................................1215 Filter................................................................................................................1215 Hydraulic Motor and Pump..............................................................................................1215 Grease Reservoir......................................................................................................1215 Pressure Reducing Valve...............................................................................................1215 Flow Control Valve....................................................................................................1215 Solenoid Valve........................................................................................................1215 Vent Valve............................................................................................................1215 Lubrication Cycle Timer...............................................................................................1215 Over Pressure Cut Off Switch..........................................................................................1215 Grease Pressure Failure Switch........................................................................................1215 Injectors.............................................................................................................1215 Relief Valve (unloader valve).........................................................................................1215 SYSTEM OPERATION..........................................................................................................1216 Normal Operation......................................................................................................1216 Lubricant Required For System.........................................................................................1217 System Priming........................................................................................................1217 Filter Assembly.......................................................................................................1217 LUBRICANT PUMP............................................................................................................1218 Pump Housing Oil Level................................................................................................1218 Pump Pressure Control.................................................................................................1218 INJECTORS (SL-1 Series “H”)...............................................................................................1219 Injector Specifications...............................................................................................1219 Injector Adjustment...................................................................................................1219 INJECTOR OPERATION....................................................................................................1220 PREVENTIVE MAINTENANCE PROCEDURES.........................................................................................1221 Daily Lubrication System Inspection...................................................................................1221 250 Hour Inspection...................................................................................................1221 1000 Hour Inspection..................................................................................................1221 SYSTEM CHECKOUT...........................................................................................................1222 Lubrication Controller Check..........................................................................................1222 Lubrication Controller Components.....................................................................................1222 Lubrication Controller Adjustment.....................................................................................1222 SYSTEM TROUBLESHOOTING CHART..................................................................................................1224 SECTION Q ALPHABETICAL INDEX..........................................................................................................1227 SECTION R SYSTEM SCHEMATICS...........................................................................................................1231 HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC.......................................................................1233 HYDRAULIC BRAKE SYSTEM SCHEMATIC..................................................................................................1234 ELECTRICAL SCHEMATICS.............................................................................................................1235
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