Komatsu 930E-4 Dump Truck Shop Manual CEBM017909 PDF

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Komatsu 930E-4 Dump Truck Shop Manual CEBM017909 – PDF DOWNLOAD

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Komatsu 930E-4 Dump Truck Shop Manual CEBM017909 – PDF DOWNLOAD 

Language : English
Pages : 1106
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 930E-4 Dump Truck Shop Manual CEBM017909 – PDF DOWNLOAD 

SERIAL NUMBERS A30462 – A30600

FOREWORD:

• 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.
• To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck
  (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and
  subtract it from the GVW. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 930E-4 Dump Truck Shop Manual CEBM017909 – PDF DOWNLOAD 

SERIAL NUMBERS A30462 – A30600

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION 9
MAJOR COMPONENTS & SPECIFICATIONS 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
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
SAFE PARKING PROCEDURES 58
NORMAL ENGINE SHUTDOWN PROCEDURE 59
DELAYED ENGINE SHUTDOWN PROCEDURE 59
SUDDEN LOSS OF ENGINE POWER 60
FUEL DEPLETION 60
DISABLED TRUCK DUMPING PROCEDURE 61
Hookup 61
Raising the Body 61
Lowering the Body 61
WARNINGS AND CAUTIONS 63
GRADE/SPEED CHART 63
KEY SWITCH 63
ROPS/FOPS 63
BATTERIES 64
CAPACITORS 64
CRUSHING HAZARD 65
CYLINDER PRESSURE 65
FILLING THE HYDRAULIC TANK 66
HYDRAULIC OIL PRESSURE 66
HOT OIL SPRAY 67
WHEEL MOTOR OIL LEVEL 67
HOT EXHAUST 67
RADIATOR 67
EMERGENCY LADDER 67
ACCUMULATOR DRAIN VALVES 67
EMERGENCY DUMP PROCEDURE 68
EMERGENCY TOWING PROCEDURE 68
WELDING 68
EMERGENCY SHUTDOWN 68
INFORMATION DISPLAY 69
WIRELESS SIGNALS 69
HIGH VOLTAGE 69
LIFTING INSTRUCTIONS 70
PRODUCT IDENTIFICATION PLATE 71
LUBRICATION CHART 72
TORQUE TABLES AND CONVERSION CHARTS 73
STORAGE AND IDLE MACHINE PREPARATION 83
SHORT TERM IDLE PERIODS 83
PREPARATION FOR STORAGE 84
REMOVAL FROM STORAGE 85
RECONDITIONING AN IDLE VEHICLE 87
ENGINE OPERATION 89
After The Engine Has Started 90
ENGINE STORAGE 91
Temporary Storage (30 Days Or Less) 91
Extended Storage (More Than 30 Days) 91
RESTORING AN ENGINE AFTER EXTENDED STORAGE 93
ELECTRIC DRIVE TRUCKS 94
Storing A Truck That Is Operational 94
Storing A Truck That Is Not Operational 95
Storing A Major Component 96
Periodic Inspections 96
Placing Equipment Into Service After Storage 96
SECTION B STRUCTURES 99
SECTION B2 STRUCTURAL COMPONENTS 101
STRUCTURAL COMPONENTS 103
PREPARATION 103
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 104
Removal 104
Installation 104
RH DECK AND RETARDING GRID 105
Removal 105
Installation 105
LH DECK 106
Removal 106
Installation 106
CENTER DECK 107
Removal 107
Installation 107
SECTION B3 DUMP BODY 109
DUMP BODY 111
DUMP BODY 111
Removal 111
Installation 112
BODY PADS 114
Body Pad Shimming Procedure 115
BODY GUIDE 116
HOIST LIMIT SWITCH 116
BODY-UP SWITCH 116
BODY RETENTION SLING 116
ROCK EJECTORS 117
Inspection 117
SECTION B4 FUEL TANK 119
FUEL TANK 121
FUEL TANK 121
Removal 121
Repair 121
Cleaning 121
Installation 121
FUEL TANK VENT ASSEMBLY 123
Disassembly 123
Assembly 123
FUEL GAUGE SENDER 124
Removal 124
Installation 124
QUICK FILL FUEL RECEIVERS 124
SECTION C ENGINE 125
SECTION C2 POWER MODULE 127
POWER MODULE 129
PREPARATION FOR REMOVAL 129
REMOVAL 134
INSTALLATION 136
HOOKUP 137
SECTION C3 COOLING SYSTEM 139
COOLING SYSTEM 141
RADIATOR 141
Removal 141
Installation 143
Filling Procedure 144
REPAIRING THE RADIATOR 144
Internal Inspection 144
External Cleaning 144
Disassembly 145
Cleaning and Inspection 146
Assembly 146
Pressure Testing 147
COOLANT SYSTEM TROUBLESHOOTING 147
SECTION C4 POWER TRAIN 149
POWER TRAIN 151
ALTERNATOR REMOVAL 151
ALTERNATOR INSTALLATION 153
Measuring Procedure 153
Joining the Alternator and Engine 155
ENGINE 156
Removal 156
Service 156
Installation 156
SECTION C5 AIR CLEANERS 157
AIR CLEANERS 159
OPERATION 159
SERVICING THE AIR CLEANERS 159
Replacing The Filter Element 159
Cleaning The Main Filter Element 161
Servicing The Precleaner Section 162
EVACUATOR VALVES (if equipped) 163
AIR INTAKE TROUBLESHOOTING 163
SECTION C7 FAN CLUTCH 165
FAN CLUTCH 167
REMOVAL & INSTALLATION TOOLING 167
DISASSEMBLY 170
CLEANING AND INSPECTION 180
ASSEMBLY 184
TEST PROCEDURE 198
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 199
SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM 201
24VDC ELECTRICAL SUPPLY SYSTEM 203
ELECTRICAL SYSTEM DESCRIPTION 203
BATTERIES 203
Maintenance and Service 203
Troubleshooting 203
BATTERY SUPPLY SYSTEM 205
24VDC Battery Charging Alternator 205
Batteries 205
24VDC Auxiliary Battery Receptacles 205
Battery Disconnect Switches 206
Isolation Diode 206
Engine Start Relay 206
24VDC to 12VDC Converter 206
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 207
Operation 207
Pressure Switch 207
Check Valve 207
Timer Solenoid 207
MAINTENANCE 208
Prelube System Operation Checks 208
Check Valve 208
Timer Solenoid 208
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 209
24VDC ELECTRIC START SYSTEM 211
CRANKING MOTORS 211
Operation 211
Removal 211
Installation 211
CRANKING MOTOR TROUBLESHOOTING 212
Preliminary Inspection 212
No-Load Test 212
Interpreting Results of Tests 213
Disassembly 213
Cleaning and Inspection 214
Armature Servicing 216
Field Coil Checks 216
Field Coil Removal 216
SOLENOID CHECKS 217
Test 217
Assembly 218
Bearing Replacement: 218
Motor Assembly: 218
Pinion Clearance 219
MAGNETIC SWITCH 219
Removal 219
Installation 219
Coil Test 220
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS 221
24 VDC ELECTRICAL SYSTEM COMPONENTS 223
TRUCK SHUTDOWN PROCEDURE 223
BRAKE WARNING BUZZER 223
AUXILIARY CONTROL CABINET COMPONENTS 223
Power Distribution Terminals 223
Engine Starter Failure Delay Timer 223
5 Minute Idle Timer 224
Pulse Voltage Modulator (PMV) 224
Control Power Relay 224
Auto Lube Timer 224
Diode Board – DB1 226
Fuse Blocks 227
Alarm Indicating Device (AID) System 227
Diode Matrix (With Sound) 228
Diode Matrix (Without Sound) 228
Hot Switch Inverter 228
Hot Switch Inverter (Not Used) 229
Temperature and Latch 229
RELAY BOARDS 230
Relay Boards RB1, RB3, RB4, RB5 230
Relay Board RB6, RB7, RB8, RB9 232
Relay Board Functions 233
BODY-UP SWITCH 235
Operation 235
Adjustment 235
Service 235
HOIST LIMIT SWITCH 236
Operation 236
Adjustment 236
Service 236
FUSES AND CIRCUIT BREAKERS 237
SECTION D10 BATTERY CHARGING ALTERNATOR 241
BATTERY CHARGING SYSTEM 245
BATTERY CHARGING SYSTEM 245
ELECTRICAL SYSTEM DESCRIPTION 245
CHARGE VOLT AND AMP VALUES 245
BATTERY 245
Maintenance and Service 245
Troubleshooting 246
Undercharging 246
Overcharging 246
Corrosion 246
Acid Levels 246
Non-Use or Storage 246
Freezing 247
BATTERY CHARGING ALTERNATOR 248
GENERAL INFORMATION 248
General Description 248
Terminal Identification and Location 249
Battery Positive (B+) 249
Battery Negative (B-) 249
DC Output (D+) 249
AC Output (R) 249
Regulator Harness Plug Identification 249
Alternator Specifications 249
Performance Curve 249
Battery/Alternator Terminology 250
WIRING DIAGRAM 252
DIMENSIONS AND TORQUE VALUES 253
PERIODIC MAINTENANCE 254
TESTING 254
GENERAL INFORMATION 254
Troubleshooting Alternator (On-Truck) 254
Equipment Required 254
Preliminary Checks 254
Test Set-up 256
Test Procedure 257
REGULATOR TESTING 258
Regulator Bypass Test (No Output) 258
Regulator Bypass Test (Amp Rating) 259
BENCH TESTING 260
Equipment 260
Identification Record 260
Advanced Troubleshooting 260
Bench Test 1: No-Load Test 260
Bench Test 2: Full Load Test 261
Bench Test 3: Regulator Bypass Test 261
STATIC TESTING 262
Equipment 262
Identification Record 262
Regulator Tester 262
Check For Shorted Power Transistor 262
Circuit Tests 263
FIELD COIL TESTS 264
Field Coil Test 1: Check for Open or Shorted Field Coil 264
Field Coil Test 2: Check For Grounded Field Coil 264
STATOR TESTS 265
Stator Test 1: Check For Stator-To-Stator Continuity 265
Stator Test 2: Check For Grounded Stators 266
THERMAL SWITCH TEST 266
Initial Test 266
Verifying a Faulty Thermal Switch 267
TROUBLESHOOTING TIPS 268
ALTERNATOR 272
ALTERNATOR REPAIR 272
Removal 272
Installation 274
Special Tools and Lubricants 274
Epoxy Adhesive 275
Liquid Threadlockers 275
Elastoplastic Silicone Resin 275
ALTERNATOR EXPLODED VIEW 277
ALTERNATOR DISASSEMBLY 279
Regulator Removal 279
Fan Removal 280
Pulley Removal 281
Anti-Drive End Housing Removal 281
Anti-Drive End Rotor Removal 283
Drive End Housing Removal 285
Drive End Rotor Removal 291
Field Coil Removal 292
Drive End and/or Anti-Drive End Stator Removal 294
CLEANING AND INSPECTION 296
ALTERNATOR ASSEMBLY 296
Anti-Drive End Stator Installation 296
Drive End Stator Installation 298
Field Coil Installation 301
Drive End Bearing Installation 303
Drive End Rotor Installation 305
Rotor and Rotor Shaft Installation 305
Drive End Housing Installation 306
Anti-Drive End Rotor Installation 310
Anti-Drive End Housing Installation 311
Regulator Installation 314
THERMAL SWITCH 315
Removal 315
Installation 317
SUPPORT STAND 317
SECTION D11 KOMTRAX PLUS 319
KOMTRAX PLUS 321
KOMTRAX PLUS BASIC FEATURES 321
Gather Data 321
Convert and Record Data 321
Communicate Data to Off-Board Systems 322
USING KOMTRAX PLUS 323
Turning KOMTRAX Plus ON 323
Normal KOMTRAX Plus Operation 323
Turning KOMTRAX Plus OFF 324
Downloading from the KOMTRAX Plus Controller 324
KOMTRAX PLUS DATA ITEMS 325
Fault Codes 325
Machine History 325
KOMTRAX Plus History 325
Snapshots 326
Manual Snapshots 326
Trends 328
Histogram (Load Map) Data 328
Haul Cycle Data 329
Alarm and Snapshot Triggers 330
Satellite Features 330
KOMTRAX PLUS DIAGNOSTIC FEATURES 332
Fault History 332
LED Digits 332
KOMTRAX PLUS CONTROLLER 332
Removal 333
Installation 333
KOMTRAX PLUS SOFTWARE 334
VHMS Tool Box Installation 334
VHMS Setting Tool Installation 334
PDM Software Installation 334
KOMTRAX PLUS INITIALIZATION PROCEDURE 335
CONTROLLER SETUP PROCEDURE 335
SNAPSHOT PROCEDURE 338
DOWNLOAD PROCEDURE 339
FTP UPLOAD PROCEDURE 340
INITIALIZATION FORMS 341
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 342
KOMTRAX PLUS CONTROLLER CHECKOUT 347
Necessary Equipment 347
Preliminary 347
KOMTRAX Plus Controller Checkout Procedure 348
ORBCOMM CONTROLLER (if equipped) 350
Removal 350
Installation 350
SECTION D12 INTERFACE MODULE 351
INTERFACE MODULE 353
Removal 353
Installation 353
SENSORS 354
Temperature Sensors 354
Pressure Sensors 354
INTERFACE MODULE SOFTWARE 355
Flashburn Program Installation 355
Interface Module Application Code Installation 356
Interface Module Realtime Data Monitor Software 356
INTERFACE MODULE CHECKOUT 357
Necessary Equipment 357
Preliminary 358
Check Digital Inputs To The Interface Module 359
Check Analog Inputs To The Interface Module 361
Check Serial Interfaces To The Interface Module 361
Check Outputs From The Interface Module 362
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING 363
INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING 365
GENERAL 365
TROUBLESHOOTING 366
Communications Networks 366
Coaxial Cable 366
FAULT CODES 366
Fault History 366
KOMTRAX Plus LED Display Fault Codes 367
Chassis Fault Codes 368
Engine Fault Codes 371
FAULT TREE ANALYSIS 377
Unable to connect to KOMTRAX Plus from laptop PC 377
Flashing Error Code N4-23 (PLM III Communications Fault) 378
Flashing Error Code N4-22 (Engine Communications Fault) 379
No Data Received By WebCARE 380
Coaxial Cable Troubleshooting 381
SECTION D14 KOMTRAX PLUS FORMS 383
KOMTRAX PLUS FORMS 385
KOMTRAX PLUS INITIALIZATION CHECK LIST 385
KOMTRAX PLUS DATA DOWNLOAD 386
KOMTRAX PLUS INITIALIZATION CHECK LIST 387
KOMTRAX PLUS INITIALIZATION FORM 389
SECTION E ELECTRIC PROPULSION SYSTEM 391
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS 393
ELECTRICAL PROPULSION SYSTEM COMPONENTS 395
GENERAL SYSTEM DESCRIPTION 395
SYSTEM COMPONENTS 397
Propulsion System Controller (PSC) 397
Truck Control Interface (TCI) 398
Diagnostic Information Display (DID) Panel 399
DID Panel Event Codes 399
PSC SOFTWARE FUNCTIONS 418
Input Processing 418
State Machine 418
DC Link State 421
Engine Control 422
ALTERNATOR FIELD CONTROL 422
Desired Three-Phase Voltage 422
Desired DC Link Voltage 422
Self-Load 423
Propel Torque Control 423
Retard Torque Control 423
Wheel Slide Control 424
Resistor Grid Control 424
Chopper Voltage Control 424
EVENT DETECTION AND PROCESSING 424
Power-On Tests 424
Initiated Tests 425
Periodic Tests 425
EVENT RESTRICTIONS 425
EVENT LOGGING AND STORAGE 425
Event History Buffer 426
Data Packs 426
To Record and Save a Data Pack to a Disk 426
Event Reset 427
SERIAL DATA COMMUNICATIONS 427
PSC – TCI Communications Processing 427
PSC – PTU Communications Processing 427
Inverter Communications Processing 428
OUTPUT PROCESSING 428
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 428
Fast Start 428
Engine Shutdown/Engine Not Running 428
Limp Home Mode 429
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 430
ELECTRONIC ACCELERATOR AND RETARD PEDALS 438
Removal 438
Installation 438
Disassembly 438
Assembly 438
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 439
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 441
AC DRIVE SYSTEM MAINTENANCE 441
NORMAL TRUCK SHUTDOWN PROCEDURE 442
SHUTDOWN AFTER SYSTEM FAILURE 442
SYSTEM CHECKOUT 443
Battery and Control Circuit Checks – Battery Power OFF 443
Battery and Control Circuit Checks – Battery Power ON 446
Checks with Key Switch OFF 447
Checks with Key Switch ON 447
CPU Battery Checks 447
MEMORY BACKUP BATTERY REPLACEMENT 448
TCI PROGRAMMING 448
PSC PROGRAMMING 449
INVERTER PROGRAMMING 449
CPU RESET 449
PSC CHECKOUT 450
PSC Digital Input Checks 450
PSC Digital Output Checks 454
TCI CHECKOUT 455
Modular Mining Communication Port Check 455
TCI Digital Input Checks 455
TCI Digital Output Tests 461
CALIBRATIONS 463
Speedometer 463
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 463
ERASING EVENTS 463
PSC 463
TCI 464
GATE DRIVER POWER CONVERTER TEST 464
LOAD TESTING 465
Preparation 465
Alternator Speed Sensor Checks 465
Battery Boost Check 465
Brake Circuit Switch Checks 466
Hoist & Steering Circuit Switch Checks 466
Link Energized Checks 466
Loadbox Test 468
TROUBLESHOOTING 472
PVM Optimum Load Curve Handshaking Troubleshooting 472
Phase Module and Chopper Module Troubleshooting 472
PHASE MODULE REPLACEMENT 473
Phase Module Removal 473
Phase Module Installation 473
SECTION G REAR AXLE, SPINDLES AND WHEELS 475
SECTION G2 TIRES AND RIMS 477
TIRES AND RIMS 479
WHEEL STUD MAINTENANCE 480
FRONT TIRES AND RIMS 481
Removal 481
Installation 482
REAR TIRES AND RIMS 483
Removal 483
Installation 484
RIM 485
Tire Removal 485
Tire Installation 485
SECTION G3 FRONT WHEEL HUB AND SPINDLE 487
FRONT WHEEL HUB AND SPINDLE 489
WHEEL HUB AND SPINDLE ASSEMBLY 489
Removal 489
Spindle Removal Procedure (off of the truck) 492
Installation 494
Disassembly 495
Cleaning and Inspection 497
Assembly 497
Wheel Bearing Adjustment 498
Brake Installation 499
Seal Assembly Gap Check 500
WHEEL SPEED SENSOR TESTING 501
STEERING CYLINDERS 502
Spherical Bearing Wear Limits 502
Removal 503
Installation 503
Bearing Replacement (Steering Cylinder and Tie Rod) 503
TIE ROD 505
Removal 505
Installation 505
Disassembly 506
Assembly 506
Toe-In Adjustment 507
TIE ROD INSPECTION AND TORQUE PROCEDURE 508
Old Style Tie Rod 508
New Style Tie Rod 509
SECTION G4 REAR AXLE MOUNTING 511
REAR AXLE MOUNTING 513
PIVOT PIN 513
Removal 513
Installation 514
PIVOT EYE BEARING 515
Removal 515
Installation 515
PIVOT EYE REPAIR 515
Removal 515
Disassembly 515
Assembly 516
Installation 516
ANTI-SWAY BAR 516
Removal 516
Disassembly 517
Cleaning and Inspection 517
Assembly 517
Installation 517
SECTION G5 REAR AXLE AND WHEEL MOTOR 519
REAR AXLE AND WHEEL MOTOR 521
REAR AXLE HOUSING 521
Preparation 521
Removal 522
Cleaning and Inspection 523
Installation 523
BLOWER PRESSURE SWITCH ADJUSTMENT 523
WHEEL MOTOR 524
Preparation 524
Removal 525
Cleaning and Inspection 527
Installation 527
WHEEL MOTOR GEAR OIL 532
Filtering Requirements 532
Particle Size Analysis 532
Flushing 532
Oil Sample Analysis 533
ELEMENT SPECIFICATION CHARTS 534
SECTION H HYDRAIR® II SUSPENSIONS 537
SECTION H2 FRONT SUSPENSIONS 539
FRONT SUSPENSION 541
Removal 541
Installation 542
Inspection 547
LOWER BEARING & SEALS 548
Removal 548
Installation 548
MAJOR SUSPENSION REBUILD 549
Disassembly 549
Assembly 550
SUSPENSION PRESSURE TEST 551
SECTION H3 REAR SUSPENSIONS 553
REAR SUSPENSIONS 555
SUSPENSION CYLINDER 556
Removal 556
Installation 558
Disassembly 558
Cleaning and Inspection 559
Assembly 559
SUSPENSION PRESSURE TEST 561
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES 563
SUSPENSION OILING AND CHARGING PROCEDURE 565
GENERAL 565
EQUIPMENT LIST 565
HYDRAIR® CHARGING KIT 566
Installation of Charging Kit 566
Removal of Charging Kit 566
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 567
FRONT SUSPENSION 567
Front Suspension Oiling 567
Front Suspension Nitrogen Charging 569
REAR SUSPENSION 570
Rear Suspension Oiling 571
Rear Suspension Nitrogen Charging 573
OIL AND NITROGEN SPECIFICATIONS CHARTS 574
SECTION J BRAKE CIRCUIT 575
SECTION J2 BRAKE CIRCUIT 577
BRAKE CIRCUIT 579
SERVICE BRAKE CIRCUIT 579
PARKING BRAKE CIRCUIT 581
BRAKE LOCK CIRCUIT 581
SECONDARY BRAKING AND AUTOMATIC APPLY 582
WARNING CIRCUIT 582
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE 585
BRAKE CIRCUIT COMPONENT SERVICE 587
BRAKE VALVE 587
Rebuild Criteria 587
Removal 588
Installation 588
Disassembly 589
Cleaning and Inspection 592
Assembly 592
Regulator Sleeve O-Ring Installation 593
BRAKE VALVE BENCH TEST AND ADJUSTMENT 595
Test Setup Procedure 596
Brake Valve Output Pressure Adjustment 596
Final Test and Adjustment 597
Installing Brake Pedal Actuator Assembly to Brake Valve 597
Installing Retard Pedal To Brake Pedal 597
DUAL RELAY VALVE 598
Removal 598
Installation 598
Disassembly 598
Cleaning and Inspection 599
Assembly 600
DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT 601
Test Setup Procedure 602
Relay Valve Output Pressure Adjustment 602
BRAKE MANIFOLD 603
Removal 603
Installation 603
Disassembly 603
Cleaning and Inspection 604
Assembly 604
BRAKE ACCUMULATORS 604
Brake Accumulator Bleeddown Procedure 604
Removal 605
Installation 605
Disassembly 606
Cleaning and Inspection 607
Assembly 607
Accumulator Charging Procedure 609
Precharge Maintenance 611
Accumulator Storage Procedures 612
Bladder Storage Procedures 612
Installing A Bladder Accumulator From Storage 612
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 613
Removal 613
Installation 613
Disassembly 613
Lever Adjustments 613
Potentiometer Check 614
Assembly 614
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE 617
BRAKE CIRCUIT CHECK-OUT PROCEDURE 619
REQUIRED EQUIPMENT 620
INITIAL SYSTEM SETUP 621
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 622
PARKING BRAKE CHECK-OUT 623
SERVICE BRAKE CHECK-OUT 624
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT 625
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 626
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 628
SECTION J5 WET DISC BRAKE ASSEMBLY 631
WET DISC BRAKE ASSEMBLY 633
OPERATION 633
BRAKE DISC WEAR INSPECTION 634
BRAKE REBUILD 635
Disassembly 635
Cleaning and Inspection 639
Assembly 640
Floating Ring Seal Assembly & Installation 645
WET DISC BRAKE BLEEDING PROCEDURE 649
SECTION J7 PARKING BRAKE 651
PARKING BRAKE 653
OPERATION 653
MAINTENANCE 654
Inspection 654
Removal 654
Installation 655
Disassembly 655
Cleaning and Inspection 655
Assembly 657
Cleaning and Inspecting New Discs 658
PARKING BRAKE BLEEDING PROCEDURE 659
SECTION L HYDRAULIC SYSTEM 661
SECTION L2 HYDRAULIC SYSTEM 663
HYDRAULIC SYSTEM 665
HYDRAULIC PUMP MODULE 665
HOIST CIRCUIT OPERATION 666
STEERING CIRCUIT OPERATION 668
DISC BRAKE COOLING SYSTEM 670
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 673
HYDRAULIC SYSTEM COMPONENT REPAIR 675
HOIST PUMP 675
Removal 675
Installation 677
Inspection 682
Assembly 682
HYDRAULIC TANK 688
Removal 688
Installation 689
HYDRAULIC TANK BREATHERS 689
HYDRAULIC TANK STRAINERS 690
Removal 690
Inspect and Clean 690
Installation 690
SECTION L4 STEERING CIRCUIT 691
STEERING CIRCUIT 693
STEERING CIRCUIT OPERATION 693
COMPONENT DESCRIPTION 694
Steering Control Unit 694
Bleeddown Manifold 695
Steering Accumulator Bleed Down Solenoid 695
Relief Valves 697
Hoist Up Limit Solenoid 697
Steering Accumulators 697
Low Precharge Warning Switch 697
High Pressure Filter 697
Quick Disconnect Ports 697
Flow Amplifier 699
FLOW AMPLIFIER SYSTEM OPERATION 700
No Steer 700
Steering Left 702
Steering Right 704
No Steer, External Shock Load 706
STEERING PUMP 708
Normal Operation 708
PRINCIPLE OF OPERATION 710
Full Pump Volume 710
Half Pump Volume 710
Neutral Position 710
Steering Pump 711
SECTION L5 STEERING CONTROL UNIT 713
STEERING CONTROL UNIT 715
REMOVAL 715
SPLINE INSPECTION 715
INSTALLATION 716
DISASSEMBLY 716
CLEANING AND INSPECTION 717
ASSEMBLY 719
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR 723
STEERING CIRCUIT COMPONENT REPAIR 725
BLEEDDOWN MANIFOLD VALVE 725
Removal 725
Installation 726
FLOW AMPLIFIER 727
Removal 727
Installation 727
Disassembly 727
Assembly 729
STEERING CYLINDERS 730
Disassembly 731
Piston Seal & Bearing Installation 731
Assembly 731
Testing 731
STEERING AND BRAKE PUMP 732
Removal 732
Installation 733
Disassembly 734
Inspection 737
Assembly 740
Driveshaft Group 741
Rotating Group 741
Valve Plate Group 742
STEERING ACCUMULATORS 744
Removal 744
Installation 744
Disassembly 745
Cleaning and Inspection 745
Assembly 746
Leak Testing 748
Charging Procedure 749
Precharge Maintenance 751
Accumulator Storage Procedures 752
Bladder Storage Procedures 752
Installing A Bladder Accumulator From Storage 752
TROUBLESHOOTING CHART 753
SECTION L7 HOIST CIRCUIT 757
HOIST CIRCUIT 759
BASIC OPERATION 759
COMPONENT DESCRIPTION 760
Hydraulic Tank 760
Hydraulic Pump 760
High Pressure Filters 760
Hoist Valve 760
Inlet Sections 760
Work Ports (Rear) Spool Section 761
Tank Ports (Front) Spool Section 761
Hoist Pilot Valve 761
Bleeddown Manifold 762
Hoist Up Limit Solenoid 762
Pilot Operated Check Valve 762
Overcenter Manifold 762
HOIST CIRCUIT OPERATION 763
Float Position Of Pilot Valve With Truck Body On Frame 764
Power Up Operation 766
Hold Operation 768
Power Down Operation 770
Float Operation 772
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR 775
HOIST CIRCUIT COMPONENT REPAIR 777
HOIST VALVE 777
Removal 777
Installation 778
O-Ring Replacement 778
INLET SECTION 779
Cleaning and Inspection 780
Assembly 780
REAR SPOOL SECTION (Work Ports) 781
Disassembly 781
Cleaning and Inspection 781
Assembly 783
FRONT SPOOL SECTION (Tank Ports) 784
Disassembly 784
Cleaning and Inspection 784
Assembly 784
HOIST PILOT VALVE 786
Removal 786
Installation 786
Disassembly 787
Cleaning and Inspection 788
Assembly 788
HOIST CYLINDERS 789
Removal 789
Installation 790
Disassembly 792
Cleaning and Inspection 793
Assembly – Quill 794
Assembly – Cylinder 796
Testing 796
OVERCENTER VALVE MANIFOLD 797
SECTION L9 HYDRAULIC SYSTEM FILTERS 799
HYDRAULIC SYSTEM FILTERS 801
HOIST CIRCUIT FILTER 801
Filter Element Replacement 801
Removal – Hoist Circuit Filter 802
Installation – Hoist Circuit Filter 802
Indicator Switch – Hoist Circuit Filter 802
STEERING CIRCUIT FILTER 803
Filter Element Replacement 803
Removal – Steering Circuit Filter 804
Installation – Steering Circuit Filter 804
Indicator Switch – Steering Circuit Filter 804
INDICATOR SWITCH 804
Test Procedure 804
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE 807
HYDRAULIC CHECKOUT PROCEDURE 809
GENERAL INFORMATION 809
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 816
Equipment Requirements 817
Pump Pressure Control Adjustments 817
Steering Control Valve and Flow Amplifier Leakage Test 818
Bleeddown Manifold Leakage Test 819
STEERING/BRAKE PUMP STROKE ADJUSTMENT 820
SHOCK AND SUCTION VALVES 820
Equipment Requirements 820
Pressure Tests 820
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 822
Equipment Requirements 822
Pressure Gauge Locations 822
Brake Cooling Circuit Test 822
Power Up Relief Pressure Test 823
Power Down Relief Pressure Test 824
Counterbalance Valve Pressure Check 825
Counterbalance Valve Adjustment 826
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 827
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 828
SECTION M OPTIONS AND SPECIAL TOOLS 829
SECTION M7 HOT START SYSTEM 831
HOT START SYSTEM 833
SYSTEM OPERATION 833
HEATER INFORMATION 834
TROUBLESHOOTING GUIDELINES 835
SECTION M8 SPECIAL TOOLS 837
HIGH VOLTAGE TOOLS 842
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 842
SECTION M19 RADIATOR SHUTTERS 845
RADIATOR SHUTTERS 847
OPERATION 847
Hydraulic Circuit 847
Electrical Circuit 848
MAINTENANCE AND REPAIR 848
TROUBLESHOOTING 849
SECTION M20 PAYLOAD METER III ™ 853
OPERATION SECTION 857
Introduction 857
Data Summary 857
Data Gathering 857
COMPONENT DESCRIPTION 858
System Diagram 858
Suspension Pressure Sensors 858
Inclinometer 858
Operator Display 858
Operator Switch 859
Speed Input 859
Body-Up Switch 859
Brake Lock Switch 859
Payload Meter 859
Communications Ports 859
Key Switch Input 860
Payload Meter Power 860
Load Lights 860
Wiring and Termination 861
TCI Outputs 861
OPERATOR’S DISPLAY AND SWITCH 862
Reading the Speedometer 862
Reading the Load Display 862
Using the Operator ID 862
Using the Load and Ton Counter 862
Total Ton Counter 862
Total Load Counter 863
Clearing the Counters 863
Viewing Live Sensor Data 863
Other Display Messages 863
PAYLOAD OPERATION & CALCULATION 864
Description of Haul Cycle States 864
Haul Cycle Description 864
Load Calculation 865
Carry Back 865
Measurement Accuracy 865
SOURCES FOR PAYLOAD ERROR 865
Payload Error 865
Loading Conditions 866
Pressure Sensors 866
Swingloads 866
Speed and Distance 866
HAUL CYCLE DATA 866
Haul Cycle Warning Flags 868
Frame Torque Data 869
Sprung Weight Data 869
Maximum Speed Data 869
Alarm Records 869
Fault Code Data 870
PC SOFTWARE OVERVIEW 871
System Configuration 871
Installing the PLMIII Software 871
DOWNLOADING DATA 872
PLM III SYSTEM CONFIGURATION 873
Starting Communications 873
Displayed Payload Units 873
Time Units 873
Connection Menu 873
Connecting to the Payload Meter 874
Configure the Payload Meter 874
Setting the Date and Time 874
Setting the Truck Type 875
Setting the Gauge Display Units 875
Setting the Frame Serial Number 875
Setting the Truck Number 875
Setting the Komatsu Distributor 875
Setting the Komatsu Customer 875
Clean Truck Tare Calibration 876
Inclinometer Calibration 876
DATA ANALYSIS 877
Creating a Query 877
Sorting on Truck Unit Number 877
Sorting on Truck Type 877
Sorting on Date Range 878
Sorting on Time Range 878
Payload Detail Screen 879
Creating Reports 879
Summary – one page report 880
Detailed – multi-page report 880
Creating Graphs 881
Exporting Data 881
CSV Export 881
Compressed 882
Importing Data 883
Deleting Haul Cycle Records 883
Viewing Alarms 884
Deleting Alarm Records 884
TROUBLESHOOTING SECTION 885
TROUBLESHOOTING 885
Viewing Active Alarms 885
Real-Time Data Display 885
Testing the Payload Lights 885
Creating Log Files of Inputs 886
Daily Inspections 886
Periodic Maintenance 886
Abnormal Displays at Power-Up 887
No Payload Display When Key Switch is Turned ON 888
No Display on Speedometer 889
No Display on Operator Display 889
No Communications With PC 890
Load Lights Don’t Light During Loading 891
Load Lights Remain ON 892
Load Lights Remain ON During Dumping 892
Display Doesn’t Clear When The Load Is Dumped 892
Calibration Problems 893
Alarm 1 – Left Front Pressure High 894
Alarm 2 – Left Front Pressure Low 894
Troubleshoot Wiring to Left Front Suspension 894
Alarm 3 – Right Front Pressure High 895
Alarm 4 – Right Front Pressure Low 895
Troubleshoot Wiring to Right Front Suspension 895
Alarm 5 -Left Rear Pressure High 896
Alarm 6 – Left Rear Pressure Low 896
Troubleshoot Wiring to Left Rear Suspension 896
Alarm 7 – Right Rear Pressure High 897
Alarm 8 – Right Rear Pressure Low 897
Troubleshoot Wiring to Right Rear Suspension 897
Alarm 9 – Inclinometer High 898
Alarm 10 – Inclinometer Low 898
Troubleshoot Inclinometer Wiring 898
Alarm 13 – Body Up Input Failure 899
Alarm 16 – Memory Write Failure 900
Alarm 17 – Memory Read Failure 900
Alarm 18 901
Alarm 19 901
Alarm 22 901
Operator Switch Doesn’t Work 902
Alarm 26 – User Switch Fault – SELECT 902
Alarm 27 – User Switch Fault – SET 902
Connector Map 903
Connectors 904
PLMIII CHECK OUT PROCEDURE 905
General Description 905
Tools Required 905
Checkout Procedure 905
PLMIII CHECKOUT PROCEDURE CONFIRMATION 909
Flashburn Programming 909
Confirmation Checklist 911
SECTION M31 RESERVE ENGINE OIL SYSTEM 913
RESERVE ENGINE OIL SYSTEM 915
Operation 916
LED Monitor Light 916
Tank Fill Control (Optional) 917
Filling Procedure (Remote Fill Feature) 917
SERVICE 918
Every 10 Hours, or once each shift: 918
Every 500 Hours 918
Changing Oil 918
TROUBLESHOOTING 919
Circuit Fuse 919
SYSTEM ELECTRICAL SCHEMATICS 920
SECTION N OPERATOR CAB 921
SECTION N2 TRUCK CAB AND COMPONENTS 923
TRUCK CAB AND COMPONENTS 925
TRUCK CAB 925
Description 925
Removal 926
Installation 927
CAB DOOR 928
Removal 928
Installation 928
Door Jamb Bolt Adjustment 929
Door Handle Plunger Adjustment 930
Replacing the Door Glass 931
Replacing the Door Handle or Latch Assembly 935
Replacing the Door Window Regulator 936
Replacing the Door and Door Hinge Seal 937
Replacing the Door Opening Seal 937
GLASS REPLACEMENT (Adhesive-Bonded Windows) 938
Recommended Tools and Supplies 938
Replacement Procedure 938
WINDSHIELD AND REAR GLASS 939
Removal 939
Installation 940
SECTION N3 CAB COMPONENTS 941
CAB COMPONENTS 943
WINDSHIELD WIPERS 943
WIPER MOTOR 943
Removal 943
Installation 943
WIPER ARM 943
Removal 943
Installation 944
WIPER LINKAGE 944
Removal 944
Installation 944
WINDSHIELD WASHER 945
Operation 945
Service 945
OPERATOR SEAT 946
Seat Belts 946
Adjustment 946
Inspection 947
Removal 947
Installation 947
PASSENGER SEAT 948
Inspection 948
Removal 948
Installation 948
SECTION N4 HEATER / AIR CONDITIONER 949
HEATER/AIR CONDITIONER 951
OPERATION 951
Fan Control Knob 951
Temperature Control Knob 951
Directional Control Knob 951
Heater Vents 951
COMPONENTS 952
Fuse and Circuit Breaker 952
Relays 952
Heater Core 952
Fan Motor And Speed Control 953
Actuators 953
Cab Air Filter 953
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 956
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 956
PRINCIPLES OF REFRIGERATION 956
Air Conditioning 956
Refrigeration – The Act Of Cooling 957
The Refrigeration Cycle 957
AIR CONDITIONER SYSTEM COMPONENTS 958
Compressor (Refrigerant Pump) 958
Service Valves 958
Condenser 958
Receiver-Drier 958
Expansion Block Valve 959
Accumulator 959
Evaporator 959
ELECTRICAL CIRCUIT 960
Thermostat 960
Compressor Clutch 960
Trinary™ Switch 961
AIR CONDITIONING SYSTEM SERVICING WARNINGS 962
SERVICE TOOLS AND EQUIPMENT 963
Recovery/Recycle Station 963
Leak Detector 963
Manifold Gauge Set 964
Installing Manifold Gauge Set 965
Purging Air From Service Hoses 965
Service Valves 966
Vacuum Pump 966
SYSTEM PERFORMANCE TEST 967
SYSTEM OIL 968
Handling and Reusing PAG Oil 968
Oil Quantity 968
Checking System Oil 968
REFRIGERANT 969
Recycled Refrigerant 969
Reclaimed Refrigerant 969
Refrigerant Quantity 970
R-134a Refrigerant Containers 970
SYSTEM LEAK TESTING 970
Electronic Leak Detector 971
Tracer Dyes 971
Soap and Water 971
RECOVERING AND RECYCLING THE REFRIGERANT 971
Draining Oil from the Previous Recovery Cycle 971
Performing the Recovery Cycle 971
Performing the Recycling Procedure 972
Evacuating and Charging the A/C System 972
SYSTEM REPAIR 972
System Flushing 972
A/C DRIVE BELT CHECKOUT PROCEDURE 973
Pulley Alignment 973
Belt Tension Check 973
COMPONENT REPLACEMENT 975
Hoses and Fittings 975
Lines 975
Expansion Valve 975
Receiver-Drier 975
Thermostat 975
Compressor 976
Accumulator 976
Clutch 976
Servicing the Compressor Clutch 977
Pulley Removal 979
Clutch Coil Check 979
Pulley Installation 979
Clutch Assembly Installation 980
EVACUATING THE SYSTEM 981
CHARGING THE A/C SYSTEM 982
TROUBLESHOOTING 983
Preliminary Checks 983
Diagnosis Of Gauge Readings And System Performance 983
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 984
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 990
SECTION N5 OPERATOR CAB CONTROLS 991
OPERATOR CAB CONTROLS 994
STEERING COLUMN 995
Removal 995
Inspection 995
Installation 996
STEERING WHEEL 996
Removal 996
Installation 996
STEERING WHEEL AND CONTROLS 998
Horn Button 998
Tilt / Telescope Lever 998
Multi-Function Turn Signal Switch 998
DYNAMIC RETARDING 999
Retarder Lever 999
Brake/Retarder Pedal 999
Throttle/Accelerator Pedal 999
GRADE/SPEED CHART 1000
OVERHEAD PANEL AND DISPLAYS 1001
Speakers 1001
Warning Alarm Buzzer 1001
Radio/CD Player 1001
Warning Indicator Light Dimmer Control 1001
Status/Warning Indicator Light Panel 1001
Air Cleaner Restriction Gauges 1001
CENTER CONSOLE 1002
Directional Control Lever 1002
Override/Fault Reset Switch 1003
Engine Shutdown Switch 1003
Window Control Switches 1003
Hoist Control Lever 1003
Retarder Speed Control (RSC) Adjustment Dial 1004
Retarder Speed Control (RSC) Switch 1004
Data Store Button 1005
KOMTRAX Plus Snapshot In Progress Light 1005
Link Energized Light 1005
Service Engine Light 1005
12V Auxiliary Power Outlets 1005
DIAGNOSTIC PORTS 1005
KOMTRAX Plus Diagnostic Port 1005
Interface Module (IM) Diagnostic Port 1005
Payload Meter Diagnostic Port 1005
Truck Control Interface (TCI) Diagnostic Port 1005
Propulsion System Controller (PSC) Diagnostic Port 1005
Engine Diagnostic Port (CENSE) 1005
Engine Diagnostic Port (QUANTUM) 1005
INSTRUMENT PANEL 1006
Control Symbols 1006
Key Switch 1008
Engine Shutdown Timer Switch 1008
Air Conditioner Compressor Switch (if equipped) 1008
Rotating Beacon Switch (optional) 1008
Heated Mirrors Switch (optional) 1008
AC Drive System Rest Switch 1009
Wheel Brake Lock Switch 1009
Hazard Warning Lights 1009
Heater/Air Conditioner Vents 1009
Engine Oil Pressure Gauge 1010
Right Turn Signal Indicator 1010
Digital Tachometer 1010
High Beam Indicator 1010
Speedometer/Payload Meter Display 1010
Left Turn Signal Indicator 1010
Coolant Temperature Gauge 1010
Lamp Check Switch 1010
Light Switch (3-Way) 1010
Ladder Light Switch 1011
Backup Light Switch 1011
Fog Light Switch 1011
Payload Meter Switch 1011
Panel Illumination Light Dimmer Switch 1011
Hydraulic Oil Temperature Gauge 1011
Engine Hourmeter 1011
Fuel Gauge 1011
OVERHEAD STATUS / WARNING INDICATORS 1012
A1 High Hydraulic Oil Temperature 1013
B1 Low Steering Pressure 1013
C1 Low Accumulator Precharge Pressure 1014
D1 Not used 1014
E1 Low Brake Pressure 1014
A2 Low Hydraulic Tank Level 1014
B2 Low Automatic Lubrication System Pressure 1014
C2 Circuit Breaker Tripped 1014
D2 Hydraulic Oil Filter Monitor 1014
E2 Low Fuel 1015
A3 Parking Brake 1015
B3 Service Brake 1015
C3 Body Up 1015
D3 Dynamic Retarding 1015
E3 Stop Engine 1015
A4 Cranking Motor Failure 1015
B4 Backup Lights 1015
C4 Engine Shutdown Timer – 5 Minute Idle 1016
D4 Retard Speed Control (RSC) Indicator 1016
E4 Check Engine 1016
A5 No Power 1016
B5 Propulsion System Warning 1016
C5 Propulsion System Temperature 1016
D5 System/Component Failure 1016
E5 Battery Charging System Failure 1017
A6 No Propel 1017
B6 Propel System At Rest 1017
C6 Propel System Not Ready 1017
D6 Reduced Propulsion 1017
E6 Retard At Continuous Level 1017
REAR AXLE LIGHT BAR 1018
Backup Lights 1018
Retard Lights 1018
Brake Light 1018
Backup Alarm 1018
KOMTRAX PLUS 1019
Operation 1019
Interface Module 1021
Basic Precautions 1021
KOMATSU WIRELESS BRIDGE (Optional) 1022
General Information 1022
Communication Setup 1022
Switching to the KWB_SETUP Network 1022
Setting the Computer Subnet Mask and IP Address 1023
Properties 1023
Setting Up the KWB 1024
Adding Encryption 1024
Final Computer Settings 1024
Data Downloading 1025
Resetting the KWB 1025
KWB Lights 1025
SECTION P LUBRICATION AND SERVICE 1027
SECTION P2 LUBRICATION AND SERVICE 1029
LUBRICATION AND SERVICE 1031
GENERAL 1031
SERVICE CAPACITIES 1031
HYDRAULIC TANK SERVICE 1031
Adding Oil 1031
COOLING SYSTEM SERVICE 1032
Radiator Filling Procedure 1032
Coolant Specifications 1032
Unacceptable Practices 1032
WHEEL MOTOR SERVICE 1032
RESERVE OIL TANK SERVICE 1033
Filling the Reserve Oil Tank (Remote Fill) 1033
Inline Screen 1033
QUICK FILL SERVICE CENTER 1034
LUBRICATION CHART 1035
10 HOUR (DAILY) INSPECTIONS 1036
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1038
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1038
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1038
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1041
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1043
5000 HOUR MAINTENANCE CHECKS 1043
SECTION P3 AUTOMATIC LUBRICATION SYSTEM 1045
AUTOMATIC LUBRICATION SYSTEM 1047
GENERAL DESCRIPTION 1047
SYSTEM COMPONENTS 1049
Filter 1049
Hydraulic Motor and Pump 1049
Grease Reservoir 1049
Pressure Reducing Valve 1049
Flow Control Valve 1049
Solenoid Valve 1049
Vent Valve 1049
Lubrication Cycle Timer 1049
Over Pressure Cut Off Switch 1049
Grease Pressure Failure Switch 1049
Injectors 1049
Relief Valve (unloader valve) 1049
SYSTEM OPERATION 1050
Normal Operation 1050
Lubricant Required For System 1051
System Priming 1051
Filter Assembly 1051
LUBRICANT PUMP 1052
Pump Housing Oil Level 1052
Pump Pressure Control 1052
INJECTORS (SL-1 Series “H”) 1053
Injector Specifications 1053
Injector Adjustment 1053
INJECTOR OPERATION 1054
PREVENTIVE MAINTENANCE PROCEDURES 1055
Daily Lubrication System Inspection 1055
250 Hour Inspection 1055
1000 Hour Inspection 1055
SYSTEM CHECKOUT 1056
Lubrication Controller Check 1056
Lubrication Controller Components 1056
Lubrication Controller Adjustment 1056
SYSTEM TROUBLESHOOTING CHART 1058
SECTION Q ALPHABETICAL INDEX 1061
SECTION R SYSTEM SCHEMATICS 1065
HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC 1067
HYDRAULIC BRAKE SYSTEM SCHEMATIC 1068
ELECTRICAL SCHEMATICS 1069

S.V 16/12/24