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KOMATSU 930E-4 Dump Truck Shop Manual SN A31164 & UP – PDF DOWNLOAD
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KOMATSU 930E-4 Dump Truck Shop Manual
SERIAL NUMBERS : A31164 & UP
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Description
KOMATSU 930E-4 Dump Truck Shop Manual
FILE DETAILS:
Language : English
Pages :1343
Downloadable : Yes
File Type : PDF
Size: 44.6 MB
Book Code: CEBM027001
KOMATSU 930E-4 DUMP TRUCK SHOP MANUAL SN A31164 & UP – PDF DOWNLOAD:
DESCRIPTION:
KOMATSU 930E-4 Dump Truck Shop Manual
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
COVER................................................................................................................................. 1 FOREWORD.............................................................................................................................. 5 TABLE OF CONTENTS..................................................................................................................... 7 SECTION A GENERAL INFORMATION......................................................................................................... 9 COMPONENTS & SPECIFICATIONS....................................................................................................... 11 MAJOR COMPONENT DESCRIPTIONS.................................................................................................. 11 Truck And Engine.......................................................................................................... 11 Main Alternator........................................................................................................... 11 AC Induction Traction Motorized Wheels.................................................................................... 11 Suspension................................................................................................................ 11 Operator's Cab............................................................................................................ 11 Power Steering............................................................................................................ 11 Dynamic Retarding......................................................................................................... 11 Brake System.............................................................................................................. 11 SPECIFICATIONS................................................................................................................ 13 ENGINE.................................................................................................................... 13 AC ELECTRIC DRIVE SYSTEM.................................................................................................. 13 DYNAMIC RETARDING......................................................................................................... 13 BATTERY ELECTRIC SYSTEM................................................................................................... 13 SERVICE CAPACITIES........................................................................................................ 13 HYDRAULIC SYSTEMS......................................................................................................... 14 SERVICE BRAKES............................................................................................................ 14 STEERING.................................................................................................................. 14 TIRES..................................................................................................................... 14 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS.............................................................................. 14 WEIGHT DISTRIBUTION....................................................................................................... 15 SAFETY............................................................................................................................ 17 GENERAL....................................................................................................................... 17 Safety Rules.............................................................................................................. 17 Safety Features........................................................................................................... 17 Fire Extinguisher And First Aid Kit....................................................................................... 17 Clothing And Personal Items............................................................................................... 17 Leaving The Operator’s Seat............................................................................................... 18 Mounting And Dismounting.................................................................................................. 18 Fire Prevention For Fuel And Oil.......................................................................................... 18 Precautions With High Temperature Fluids.................................................................................. 19 Asbestos Dust Hazard Prevention........................................................................................... 19 Prevention Of Injury By Work Equipment.................................................................................... 19 Unauthorized Modification................................................................................................. 19 Precautions When Using ROPS............................................................................................... 19 Precautions For Attachments............................................................................................... 20 Precautions For Starting The Truck........................................................................................ 20 PRECAUTIONS BEFORE OPERATION.................................................................................................. 20 Safety At The Worksite.................................................................................................... 20 Fire Prevention........................................................................................................... 21 Ventilation In Enclosed Areas............................................................................................. 21 Preparing For Operation................................................................................................... 21 Mirrors, Windows And Lights............................................................................................... 21 In The Operator Cab (Before Starting The Engine).......................................................................... 21 Seat Belts................................................................................................................ 21 OPERATING THE TRUCK........................................................................................................... 22 When Starting The Engine.................................................................................................. 22 General Truck Operation................................................................................................... 22 Ensuring Good Visibility.................................................................................................. 22 Traveling................................................................................................................. 23 Traveling In Reverse...................................................................................................... 23 Traveling On Slopes....................................................................................................... 23 Operating On Snow Or Ice.................................................................................................. 23 Avoid Damage To Dump Body................................................................................................. 23 Driving Near High Voltage Cables.......................................................................................... 24 Working On Loose Ground................................................................................................... 24 When Dumping.............................................................................................................. 24 When Loading.............................................................................................................. 24 Parking The Truck......................................................................................................... 24 Towing.................................................................................................................... 24 WORKING NEAR BATTERIES........................................................................................................ 25 Battery Hazard Prevention................................................................................................. 25 Jump Starting With Booster Cables......................................................................................... 26 Jump Starting With Receptacles............................................................................................ 26 BEFORE PERFORMING MAINTENANCE................................................................................................. 27 Stopping The Engine Before Service........................................................................................ 27 Warning Tag............................................................................................................... 27 Proper Tools.............................................................................................................. 27 Use of Tie-Off Anchor During Maintenance and Repair....................................................................... 27 Securing The Dump Body.................................................................................................... 28 WHILE PERFORMING MAINTENANCE.................................................................................................. 29 Keep The Truck Clean...................................................................................................... 29 Attachments............................................................................................................... 29 Working Under The Truck................................................................................................... 29 Rotating Fan And Belts.................................................................................................... 29 Waste Materials........................................................................................................... 29 Adding Fuel Or Oil........................................................................................................ 30 Radiator Coolant Level.................................................................................................... 30 Use Of Lighting........................................................................................................... 30 Precautions With The Battery.............................................................................................. 30 Handling High Pressure Hoses.............................................................................................. 30 Precautions With High Pressure Oil........................................................................................ 30 Performing Maintenance Near High Temperature Or High Pressure............................................................. 30 TIRES......................................................................................................................... 31 Handling Tires............................................................................................................ 31 Tire Maintenance.......................................................................................................... 31 Storing Tires After Removal............................................................................................... 31 WHEN REPAIRS ARE NECESSARY.................................................................................................... 32 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS............................................................................ 33 Preliminary Procedures Before Welding or Performing Maintenance........................................................... 33 Engine Shutdown Procedure Before Welding or Performing Maintenance........................................................ 33 CAPACITOR DISCHARGE SYSTEM.................................................................................................... 35 Necessary Tools........................................................................................................... 35 Warnings And Cautions..................................................................................................... 36 Manual DC Link Capacitor Discharge Procedure.............................................................................. 37 Failure of the Discharge System........................................................................................... 39 Manual Discharge of Capacitors............................................................................................ 40 Short Isolated Capacitor Terminals........................................................................................ 42 OPERATING INSTRUCTIONS............................................................................................................ 43 PREPARING FOR OPERATION....................................................................................................... 43 WALK AROUND INSPECTION........................................................................................................ 43 RETRACTABLE LADDER SYSTEM (Optional).......................................................................................... 47 Description............................................................................................................... 47 Normal Operation.......................................................................................................... 47 General Safety............................................................................................................ 47 IN-CAB CONTROL PANEL.......................................................................................................... 48 Digital Display Screen.................................................................................................... 48 Command Buttons........................................................................................................... 48 USING THE IN-CAB CONTROL PANEL................................................................................................ 49 Raising the Ladder........................................................................................................ 50 Lowering the Ladder....................................................................................................... 50 USING THE GROUND LEVEL CONTROL BOX............................................................................................ 51 Raising the Ladder........................................................................................................ 51 Lowering the Ladder....................................................................................................... 51 EMERGENCY OPERATION........................................................................................................... 51 ENGINE START-UP............................................................................................................... 52 AFTER ENGINE HAS STARTED...................................................................................................... 53 PRE-SHIFT BRAKE CHECK......................................................................................................... 53 Events.................................................................................................................... 53 OPERATION..................................................................................................................... 54 Description............................................................................................................... 54 Brake Test Exit Criteria.................................................................................................. 54 PERFORMING THE BRAKE TESTS.................................................................................................... 55 Setup..................................................................................................................... 55 Service Brake Test........................................................................................................ 55 Parking Brake Test........................................................................................................ 56 Retard System Test........................................................................................................ 57 EMERGENCY STEERING SYSTEM..................................................................................................... 57 Operation................................................................................................................. 57 Pre-Operation Testing..................................................................................................... 57 MACHINE OPERATION SAFETY PRECAUTIONS.......................................................................................... 58 OPERATING ON THE HAUL ROAD.................................................................................................... 59 STARTING ON A GRADE WITH A LOADED TRUCK....................................................................................... 60 PASSING....................................................................................................................... 60 LOADING....................................................................................................................... 60 Overload Speed Limit Function............................................................................................. 60 DUMPING....................................................................................................................... 61 Raising The Dump Body..................................................................................................... 61 Lowering The Dump Body (When dumping on flat ground)...................................................................... 62 Lowering The Dump Body (When dumping over a berm or into a crusher)....................................................... 62 TOWING........................................................................................................................ 63 Special Wiring Harness.................................................................................................... 63 SAFE PARKING PROCEDURES....................................................................................................... 65 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................................................................. 65 SUDDEN LOSS OF ENGINE POWER................................................................................................... 66 FUEL DEPLETION................................................................................................................ 66 DISABLED TRUCK DUMPING PROCEDURE.............................................................................................. 67 Hookup.................................................................................................................... 67 Raising the Body.......................................................................................................... 67 Lowering the Body......................................................................................................... 67 WARNINGS AND CAUTIONS............................................................................................................. 69 GRADE/SPEED CHART............................................................................................................. 69 KEY SWITCH.................................................................................................................... 69 ROPS/FOPS..................................................................................................................... 69 BATTERIES..................................................................................................................... 70 CAPACITORS.................................................................................................................... 70 CRUSHING HAZARD............................................................................................................... 71 CYLINDER PRESSURE............................................................................................................. 71 FILLING THE HYDRAULIC TANK.................................................................................................... 72 HYDRAULIC OIL PRESSURE........................................................................................................ 72 HOT OIL SPRAY................................................................................................................. 73 WHEEL MOTOR OIL LEVEL......................................................................................................... 73 HOT EXHAUST................................................................................................................... 73 RADIATOR...................................................................................................................... 73 EMERGENCY LADDER.............................................................................................................. 73 ACCUMULATOR DRAIN VALVES...................................................................................................... 73 EMERGENCY DUMP PROCEDURE...................................................................................................... 74 EMERGENCY TOWING PROCEDURE.................................................................................................... 74 WELDING....................................................................................................................... 74 EMERGENCY SHUTDOWN............................................................................................................ 74 INFORMATION DISPLAY........................................................................................................... 75 WIRELESS SIGNALS.............................................................................................................. 75 HIGH VOLTAGE.................................................................................................................. 75 LIFTING INSTRUCTIONS.......................................................................................................... 76 PRODUCT IDENTIFICATION PLATE.................................................................................................. 77 LUBRICATION CHART............................................................................................................. 78 TORQUE TABLES AND CONVERSION CHARTS............................................................................................... 79 STORAGE AND IDLE MACHINE PREPARATION.............................................................................................. 89 SHORT TERM IDLE PERIODS....................................................................................................... 89 PREPARATION FOR STORAGE....................................................................................................... 90 REMOVAL FROM STORAGE.......................................................................................................... 91 RECONDITIONING AN IDLE VEHICLE................................................................................................ 93 ENGINE OPERATION.............................................................................................................. 95 After The Engine Has Started.............................................................................................. 96 ENGINE STORAGE................................................................................................................ 97 Temporary Storage (30 Days Or Less)....................................................................................... 97 Extended Storage (More Than 30 Days)...................................................................................... 97 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................................................................... 99 ELECTRIC DRIVE TRUCKS......................................................................................................... 100 Storing A Truck That Is Operational....................................................................................... 100 Storing A Truck That Is Not Operational................................................................................... 101 Storing A Major Component................................................................................................. 102 Periodic Inspections...................................................................................................... 102 Placing Equipment Into Service After Storage.............................................................................. 102 SECTION B STRUCTURES.................................................................................................................. 105 SECTION B2 STRUCTURAL COMPONENTS.................................................................................................. 107 STRUCTURAL COMPONENTS......................................................................................................... 109 PREPARATION............................................................................................................... 109 DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY................................................................................. 110 Removal............................................................................................................... 110 Installation.......................................................................................................... 110 RH DECK AND RETARDING GRID................................................................................................ 111 Removal............................................................................................................... 111 Installation.......................................................................................................... 111 LH DECK................................................................................................................... 112 Removal............................................................................................................... 112 Installation.......................................................................................................... 112 CENTER DECK............................................................................................................... 113 Removal............................................................................................................... 113 Installation.......................................................................................................... 113 SECTION B3 DUMP BODY.............................................................................................................. 115 DUMP BODY..................................................................................................................... 117 DUMP BODY................................................................................................................. 117 Removal............................................................................................................... 117 Installation.......................................................................................................... 118 BODY PADS................................................................................................................. 119 Body Pad Shimming Procedure........................................................................................... 120 BODY GUIDE................................................................................................................ 121 HOIST LIMIT SWITCH........................................................................................................ 121 BODY-UP SWITCH............................................................................................................ 121 BODY RETENTION SLING...................................................................................................... 121 ROCK EJECTORS............................................................................................................. 122 Inspection............................................................................................................ 122 SECTION B4 FUEL TANK (S/N A31165 - A31494)........................................................................................ 123 FUEL TANK..................................................................................................................... 125 FUEL TANK................................................................................................................. 125 Removal............................................................................................................... 125 Repair................................................................................................................ 125 Cleaning.............................................................................................................. 125 Installation.......................................................................................................... 125 FUEL TANK VENT ASSEMBLY................................................................................................... 127 Disassembly........................................................................................................... 127 Assembly.............................................................................................................. 127 FUEL GAUGE SENDER......................................................................................................... 128 Removal............................................................................................................... 128 Installation.......................................................................................................... 128 QUICK FILL FUEL RECEIVERS................................................................................................. 128 SECTION B4 FUEL TANK (S/N A31496 & UP)............................................................................................ 129 FUEL TANK..................................................................................................................... 130 Removal................................................................................................................... 130 Installation.............................................................................................................. 130 Repair.................................................................................................................... 132 Cleaning.................................................................................................................. 132 FUEL TANK BREATHER VALVE.................................................................................................. 132 Disassembly........................................................................................................... 132 Assembly.............................................................................................................. 132 FUEL GAUGE SENDER......................................................................................................... 133 Removal............................................................................................................... 133 Operation............................................................................................................. 134 Specifications:....................................................................................................... 134 QUICK FILL FUEL RECEIVERS................................................................................................. 135 SECTION C ENGINE...................................................................................................................... 137 SECTION C2 POWER MODULE........................................................................................................... 139 POWER MODULE.................................................................................................................. 141 PREPARATION FOR REMOVAL................................................................................................... 141 REMOVAL................................................................................................................... 146 INSTALLATION.............................................................................................................. 148 HOOKUP.................................................................................................................... 149 SECTION C3 COOLING SYSTEM......................................................................................................... 151 COOLING SYSTEM................................................................................................................ 153 RADIATOR.................................................................................................................. 153 Removal............................................................................................................... 153 Installation.......................................................................................................... 155 Filling Procedure..................................................................................................... 156 REPAIRING THE RADIATOR.................................................................................................... 156 Internal Inspection................................................................................................... 156 External Cleaning..................................................................................................... 156 Disassembly........................................................................................................... 157 Cleaning and Inspection............................................................................................... 158 Assembly.............................................................................................................. 158 Pressure Testing...................................................................................................... 159 COOLANT SYSTEM TROUBLESHOOTING............................................................................................ 159 SECTION C4 POWER TRAIN............................................................................................................ 161 POWER TRAIN................................................................................................................... 163 ALTERNATOR REMOVAL........................................................................................................ 163 ALTERNATOR INSTALLATION................................................................................................... 165 Measuring Procedure................................................................................................... 165 Joining the Alternator and Engine..................................................................................... 167 ENGINE.................................................................................................................... 168 Removal............................................................................................................... 168 Service............................................................................................................... 168 Installation.......................................................................................................... 168 SECTION C5 AIR CLEANERS........................................................................................................... 169 AIR CLEANERS.................................................................................................................. 171 OPERATION................................................................................................................. 171 SERVICING THE AIR CLEANERS................................................................................................ 171 Replacing The Elements................................................................................................ 172 AIR CLEANER ASSEMBLY CLEANING............................................................................................. 173 Primary Element Cleaning.............................................................................................. 173 Precleaner Section Cleaning........................................................................................... 175 AIR INTAKE TROUBLESHOOTING................................................................................................ 176 SECTION C7 FAN CLUTCH............................................................................................................. 177 FAN CLUTCH.................................................................................................................... 179 REMOVAL & INSTALLATION TOOLING............................................................................................ 179 DISASSEMBLY............................................................................................................... 182 CLEANING AND INSPECTION................................................................................................... 192 ASSEMBLY.................................................................................................................. 196 TEST PROCEDURE............................................................................................................ 210 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION).................................................................................... 211 SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM......................................................................................... 213 24VDC ELECTRIC SUPPLY SYSTEM.................................................................................................. 215 ELECTRICAL SYSTEM DESCRIPTION............................................................................................. 215 BATTERIES................................................................................................................. 215 Maintenance and Service............................................................................................... 215 Troubleshooting....................................................................................................... 215 BATTERY SUPPLY SYSTEM..................................................................................................... 217 24VDC Battery Charging Alternator..................................................................................... 217 Batteries............................................................................................................. 217 Engine Start Relays................................................................................................... 217 24VDC Auxiliary Battery Receptacles................................................................................... 217 Battery Disconnect Switches........................................................................................... 217 24VDC to 12VDC Converter.............................................................................................. 218 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)....................................................................... 218 Operation............................................................................................................. 218 Pressure Switch....................................................................................................... 218 Check Valve........................................................................................................... 219 Timer Solenoid........................................................................................................ 219 MAINTENANCE............................................................................................................... 219 Prelube System Operation Checks....................................................................................... 219 Check Valve........................................................................................................... 219 Timer Solenoid........................................................................................................ 219 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT................................................................................ 220 24VDC ELECTRIC START SYSTEM................................................................................................... 222 CRANKING MOTORS........................................................................................................... 222 Operation............................................................................................................. 222 Removal............................................................................................................... 222 Installation.......................................................................................................... 222 CRANKING MOTOR TROUBLESHOOTING............................................................................................ 223 Preliminary Inspection................................................................................................ 223 No-Load Test.......................................................................................................... 223 Interpreting Results of Tests......................................................................................... 224 Disassembly........................................................................................................... 224 Cleaning and Inspection............................................................................................... 225 Armature Servicing.................................................................................................... 227 Field Coil Checks..................................................................................................... 227 Field Coil Removal.................................................................................................... 227 SOLENOID CHECKS........................................................................................................... 228 Test.................................................................................................................. 228 Assembly.............................................................................................................. 229 Bearing Replacement:.................................................................................................. 229 Motor Assembly:....................................................................................................... 229 Pinion Clearance...................................................................................................... 230 MAGNETIC SWITCH........................................................................................................... 230 Removal............................................................................................................... 230 Installation.......................................................................................................... 230 Coil Test............................................................................................................. 231 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS..................................................................................... 233 24 VDC ELECTRICAL SYSTEM COMPONENTS........................................................................................... 235 BRAKE WARNING BUZZER...................................................................................................... 235 AUXILIARY CONTROL CABINET COMPONENTS...................................................................................... 235 Power Distribution Terminals.......................................................................................... 235 Control Power Relay................................................................................................... 235 Auto Lube Timer....................................................................................................... 235 Ground Level Power Relay.............................................................................................. 235 Diode Board - DB1..................................................................................................... 237 Fuse Blocks........................................................................................................... 238 Alarm Indicating Device (AID) System.................................................................................. 238 RELAY BOARDS.............................................................................................................. 241 Relay Boards RB1, RB3, RB4, RB5....................................................................................... 241 Relay Board RB6, RB7, RB8, RB9........................................................................................ 243 Relay Board Functions................................................................................................. 244 BODY-UP SWITCH............................................................................................................ 246 Operation............................................................................................................. 246 Adjustment............................................................................................................ 246 Service............................................................................................................... 246 HOIST LIMIT SWITCH........................................................................................................ 247 Operation............................................................................................................. 247 Adjustment............................................................................................................ 247 Service............................................................................................................... 247 FUSE BLOCKS AND CIRCUIT BREAKERS.......................................................................................... 248 SECTION D11 KOMTRAX PLUS.......................................................................................................... 251 KOMTRAX PLUS.................................................................................................................. 253 KOMTRAX PLUS BASIC FEATURES............................................................................................... 253 Gather Data........................................................................................................... 253 Convert and Record Data............................................................................................... 253 Communicate Data to Off-Board Systems................................................................................. 254 USING KOMTRAX PLUS........................................................................................................ 255 Turning KOMTRAX Plus ON............................................................................................... 255 Normal KOMTRAX Plus Operation......................................................................................... 255 Turning KOMTRAX Plus OFF.............................................................................................. 256 Downloading from the KOMTRAX Plus Controller.......................................................................... 256 KOMTRAX PLUS DATA ITEMS................................................................................................... 257 Fault Codes........................................................................................................... 257 Machine History....................................................................................................... 257 KOMTRAX Plus History.................................................................................................. 257 Snapshots............................................................................................................. 258 Manual Snapshots...................................................................................................... 258 Trends................................................................................................................ 260 Histogram (Load Map) Data............................................................................................. 260 Haul Cycle Data....................................................................................................... 261 Alarm and Snapshot Triggers........................................................................................... 262 Satellite Features.................................................................................................... 262 KOMTRAX PLUS DIAGNOSTIC FEATURES.......................................................................................... 264 Fault History......................................................................................................... 264 LED Digits............................................................................................................ 264 KOMTRAX PLUS CONTROLLER................................................................................................... 264 Removal............................................................................................................... 265 Installation.......................................................................................................... 265 KOMTRAX PLUS SOFTWARE..................................................................................................... 266 VHMS Tool Box Installation............................................................................................ 266 VHMS Setting Tool Installation........................................................................................ 266 PDM Software Installation............................................................................................. 266 KOMTRAX PLUS INITIALIZATION PROCEDURE..................................................................................... 267 CONTROLLER SETUP PROCEDURE............................................................................................ 267 SNAPSHOT PROCEDURE.................................................................................................... 270 DOWNLOAD PROCEDURE.................................................................................................... 271 FTP UPLOAD PROCEDURE.................................................................................................. 272 INITIALIZATION FORMS.................................................................................................. 273 WHEN REPLACING A KOMTRAX PLUS CONTROLLER.................................................................................. 274 KOMTRAX PLUS CONTROLLER CHECKOUT.......................................................................................... 279 Necessary Equipment................................................................................................... 279 Preliminary........................................................................................................... 279 KOMTRAX Plus Controller Checkout Procedure............................................................................ 280 ORBCOMM CONTROLLER (if equipped).......................................................................................... 282 Removal............................................................................................................... 282 Installation.......................................................................................................... 282 SECTION D12 INTERFACE MODULE...................................................................................................... 283 INTERFACE MODULE.............................................................................................................. 285 Removal................................................................................................................... 285 Installation.............................................................................................................. 285 SENSORS....................................................................................................................... 286 Temperature Sensors....................................................................................................... 286 Pressure Sensors.......................................................................................................... 286 INTERFACE MODULE SOFTWARE..................................................................................................... 287 Flashburn Program Installation............................................................................................ 287 Interface Module Application Code Installation............................................................................ 288 Interface Module Realtime Data Monitor Software........................................................................... 288 INTERFACE MODULE CHECKOUT..................................................................................................... 289 Necessary Equipment....................................................................................................... 289 Preliminary............................................................................................................... 290 Check Digital Inputs To The Interface Module.............................................................................. 291 Check Analog Inputs To The Interface Module............................................................................... 294 Check Serial Interfaces To The Interface Module........................................................................... 294 Check Outputs From The Interface Module................................................................................... 295 SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX............................................................... 297 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING............................................................................. 299 GENERAL................................................................................................................... 299 TROUBLESHOOTING........................................................................................................... 300 Communications Networks............................................................................................... 300 Coaxial Cable......................................................................................................... 300 FAULT CODES............................................................................................................... 300 Fault History......................................................................................................... 300 KOMTRAX Plus LED Display Fault Codes.................................................................................. 301 Chassis Fault Codes................................................................................................... 302 Engine Fault Codes.................................................................................................... 306 FAULT TREE ANALYSIS....................................................................................................... 312 Unable to connect to KOMTRAX Plus from laptop PC...................................................................... 312 Flashing Error Code N4-23 (PLM III Communications Fault).............................................................. 313 Flashing Error Code N4-22 (Engine Communications Fault)............................................................... 314 No Data Received By WebCARE........................................................................................... 315 Coaxial Cable Troubleshooting......................................................................................... 316 SECTION D14 KOMTRAX PLUS FORMS.................................................................................................... 317 KOMTRAX PLUS FORMS............................................................................................................ 319 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 319 KOMTRAX PLUS DATA DOWNLOAD................................................................................................ 320 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 321 KOMTRAX PLUS INITIALIZATION FORM.......................................................................................... 323 SECTION E ELECTRIC PROPULSION SYSTEM.................................................................................................. 325 SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS.................................................................................. 327 ELECTRICAL PROPULSION SYSTEM COMPONENTS....................................................................................... 329 GENERAL SYSTEM DESCRIPTION................................................................................................ 329 SYSTEM COMPONENTS......................................................................................................... 331 Propulsion System Controller (PSC).................................................................................... 331 Truck Control Interface (TCI)......................................................................................... 332 Diagnostic Information Display (DID) Panel............................................................................ 333 DID Panel Event Codes................................................................................................. 333 PSC SOFTWARE FUNCTIONS.................................................................................................... 352 Input Processing...................................................................................................... 352 State Machine......................................................................................................... 352 DC Link State......................................................................................................... 355 Engine Control........................................................................................................ 356 ALTERNATOR FIELD CONTROL.................................................................................................. 356 Desired Three-Phase Voltage........................................................................................... 356 Desired DC Link Voltage............................................................................................... 356 Self-Load............................................................................................................. 357 Propel Torque Control................................................................................................. 357 Retard Torque Control................................................................................................. 357 Wheel Slide Control................................................................................................... 358 Resistor Grid Control................................................................................................. 358 Chopper Voltage Control............................................................................................... 358 EVENT DETECTION AND PROCESSING............................................................................................ 358 Power-On Tests........................................................................................................ 358 Initiated Tests....................................................................................................... 359 Periodic Tests........................................................................................................ 359 EVENT RESTRICTIONS........................................................................................................ 359 EVENT LOGGING AND STORAGE................................................................................................. 359 Event History Buffer.................................................................................................. 360 Data Packs............................................................................................................ 360 To Record and Save a Data Pack to a Disk.............................................................................. 360 Event Reset........................................................................................................... 361 SERIAL DATA COMMUNICATIONS................................................................................................ 361 PSC - TCI Communications Processing................................................................................... 361 PSC - PTU Communications Processing................................................................................... 361 Inverter Communications Processing.................................................................................... 362 OUTPUT PROCESSING......................................................................................................... 362 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS.................................................................................. 362 Fast Start............................................................................................................ 362 Engine Shutdown/Engine Not Running.................................................................................... 362 Limp Home Mode........................................................................................................ 363 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS..................................................................... 364 ELECTRONIC ACCELERATOR AND RETARD PEDALS.................................................................................. 372 Removal............................................................................................................... 372 Installation.......................................................................................................... 372 Disassembly........................................................................................................... 372 Assembly.............................................................................................................. 372 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.......................................................................... 373 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE................................................................................. 375 AC DRIVE SYSTEM MAINTENANCE............................................................................................... 375 NORMAL TRUCK SHUTDOWN PROCEDURE........................................................................................... 376 SHUTDOWN AFTER SYSTEM FAILURE............................................................................................. 376 SYSTEM CHECKOUT........................................................................................................... 377 Battery and Control Circuit Checks - Battery Power OFF................................................................ 377 Battery and Control Circuit Checks - Battery Power ON................................................................. 380 Checks with Key Switch OFF............................................................................................ 381 Checks with Key Switch ON............................................................................................. 381 CPU Battery Checks.................................................................................................... 381 MEMORY BACKUP BATTERY REPLACEMENT......................................................................................... 382 TCI PROGRAMMING........................................................................................................... 382 PSC PROGRAMMING........................................................................................................... 383 INVERTER PROGRAMMING...................................................................................................... 383 CPU RESET................................................................................................................. 383 PSC CHECKOUT.............................................................................................................. 384 PSC Digital Input Checks.............................................................................................. 384 PSC Digital Output Checks............................................................................................. 388 TCI CHECKOUT.............................................................................................................. 389 Modular Mining Communication Port Check............................................................................... 389 TCI Digital Input Checks.............................................................................................. 389 TCI Digital Output Tests.............................................................................................. 395 CALIBRATIONS.............................................................................................................. 397 Speedometer........................................................................................................... 397 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial.................................................................. 397 ERASING EVENTS............................................................................................................ 397 PSC................................................................................................................... 397 TCI................................................................................................................... 398 GATE DRIVER POWER CONVERTER TEST.......................................................................................... 398 LOAD TESTING.............................................................................................................. 399 Preparation........................................................................................................... 399 Alternator Speed Sensor Checks........................................................................................ 399 Battery Boost Check................................................................................................... 399 Brake Circuit Switch Checks........................................................................................... 400 Hoist & Steering Circuit Switch Checks................................................................................ 400 Link Energized Checks................................................................................................. 400 Loadbox Test.......................................................................................................... 402 TROUBLESHOOTING........................................................................................................... 406 PVM Optimum Load Curve Handshaking Troubleshooting.................................................................... 406 Phase Module and Chopper Module Troubleshooting....................................................................... 406 PHASE MODULE REPLACEMENT.................................................................................................. 407 Phase Module Removal.................................................................................................. 407 Phase Module Installation............................................................................................. 407 SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146)................................................................................ 409 Fault Code A001: Left front suspension pressure sensor signal is high......................................................... 411 Related circuit diagram................................................................................................... 411 Fault Code A002: Left front suspension pressure sensor signal is low.......................................................... 412 Related circuit diagram................................................................................................... 412 Fault Code A003: Right front suspension pressure sensor signal is high........................................................ 413 Related circuit diagram................................................................................................... 413 Fault Code A004: Right front suspension pressure sensor signal is low......................................................... 414 Related circuit diagram................................................................................................... 414 Fault Code A005: Left rear suspension pressure sensor signal is high.......................................................... 415 Related circuit diagram................................................................................................... 415 Fault Code A006: Left rear suspension pressure sensor signal is low........................................................... 416 Related circuit diagram................................................................................................... 416 Fault Code A007: Right rear suspension pressure sensor signal is high......................................................... 417 Related circuit diagram................................................................................................... 417 Fault Code A008: Right rear suspension pressure sensor signal is low.......................................................... 418 Related circuit diagram................................................................................................... 418 Fault Code A009: Incline sensor signal is high................................................................................ 419 Related circuit diagram................................................................................................... 419 Fault Code A010: Incline sensor signal is low................................................................................. 420 Related circuit diagram................................................................................................... 420 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 421 Related circuit diagram................................................................................................... 421 Fault Code A013: Body up switch has failed.................................................................................... 422 Related circuit diagram................................................................................................... 422 Fault Code A014: Payload meter checksum computation has failed................................................................ 423 Related circuit diagram................................................................................................... 423 Fault Code A016: Payload meter write to flash memory has failed............................................................... 424 Related circuit diagram................................................................................................... 424 Fault Code A017: Payload meter flash memory read has failed................................................................... 425 Related circuit diagram................................................................................................... 425 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 426 Related circuit diagram................................................................................................... 427 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 428 Related circuit diagram................................................................................................... 429 Fault Code A022: Carryback load is excessive.................................................................................. 430 Related circuit diagram................................................................................................... 431 Fault Code A026: Payload meter user select switch has failed.................................................................. 432 Related circuit diagram................................................................................................... 432 Fault Code A027: Payload meter user clear switch has failed................................................................... 433 Related circuit diagram................................................................................................... 433 Fault Code A101: High pressure detected across a hydraulic pump filter........................................................ 434 Related circuit diagram................................................................................................... 435 Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level................................... 436 Related circuit diagram................................................................................................... 437 Fault Code A107: GE has generated a propel system caution..................................................................... 438 Related circuit diagram................................................................................................... 439 Fault Code A108: GE has generated a propel system temperature caution......................................................... 440 Related circuit diagram................................................................................................... 441 Fault Code A109: GE has generated a propel system reduced level signal........................................................ 442 Related circuit diagram................................................................................................... 443 Fault Code A115: Low steering precharge pressure is detected.................................................................. 444 Related circuit diagram................................................................................................... 445 Fault Code A123: GE has generated a reduced retarding caution................................................................. 446 Related circuit diagram................................................................................................... 447 Fault Code A124: GE has generated a no propel / no retard warning............................................................. 448 Related circuit diagram................................................................................................... 449 Fault Code A125: GE has generated a no propel warning......................................................................... 450 Related circuit diagram................................................................................................... 451 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 452 Related circuit diagram................................................................................................... 453 Fault Code A127: IM furnished +5 volt output for sensors is low............................................................... 454 Related circuit diagram................................................................................................... 455 Fault Code A128: IM furnished +5 volt output for sensors is high.............................................................. 456 Related circuit diagram................................................................................................... 457 Fault Code A139, A310: Low fuel level warning................................................................................. 458 Related circuit diagram................................................................................................... 459 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 460 Related circuit diagram................................................................................................... 461 Fault Code A146: Hydraulic temperature sensors cause posting of this faultl................................................... 462 Related circuit diagram................................................................................................... 463 SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216)................................................................................ 465 Fault Code A152: Starter failure.............................................................................................. 466 Related circuit diagram................................................................................................... 467 Fault Code A153: Battery voltage is low with truck in operation............................................................... 468 Related circuit diagram................................................................................................... 469 Fault Code A154: Battery charging voltage is excessive........................................................................ 470 Related circuit diagram................................................................................................... 471 Fault Code A155: Battery charging voltage is low.............................................................................. 472 Related circuit diagram................................................................................................... 473 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 474 Related circuit diagram................................................................................................... 475 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 476 Related circuit diagram................................................................................................... 477 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 478 Related circuit diagram................................................................................................... 479 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 480 Related circuit diagram................................................................................................... 481 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 482 Related circuit diagram................................................................................................... 483 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 484 Related circuit diagram................................................................................................... 484 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 485 Related circuit diagram................................................................................................... 485 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 486 Related circuit diagram................................................................................................... 486 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 487 Related circuit diagram................................................................................................... 487 Fault Code A184: J1939 data link is not connected............................................................................. 488 Related circuit diagram................................................................................................... 489 Fault Code A190: Auto lube control has detected an incomplete lube cycle...................................................... 490 Related circuit diagram................................................................................................... 491 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 492 Related circuit diagram................................................................................................... 493 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 494 Related circuit diagram....................................................................................................... 495 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 496 Related circuit diagram....................................................................................................... 497 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 498 Related circuit diagram....................................................................................................... 499 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 500 Related circuit diagram................................................................................................... 500 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 501 Related circuit diagram................................................................................................... 501 Fault Code A200: Steering pressure sensor is high............................................................................. 502 Related circuit diagram................................................................................................... 502 Fault Code A201: Brake pressure sensor is high................................................................................ 503 Related circuit diagram................................................................................................... 503 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 504 Related circuit diagram................................................................................................... 504 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 505 Related circuit diagram................................................................................................... 505 Fault Code A204: Steering pressure sensor is low.............................................................................. 506 Related circuit diagram................................................................................................... 506 Fault Code A205: Brake pressure sensor is low................................................................................. 507 Related circuit diagram................................................................................................... 507 Fault Code A206: Ambient temperature sensor is high........................................................................... 508 Related circuit diagram................................................................................................... 508 Fault Code A207: Ambient temperature sensor is low............................................................................ 509 Related circuit diagram................................................................................................... 509 Fault Code A212: Bad truck speed signal....................................................................................... 510 Related circuit diagram................................................................................................... 511 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 512 Related circuit diagram................................................................................................... 514 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 516 Related circuit diagram................................................................................................... 518 Fault Code A215: Brake auto apply relay circuit is defective.................................................................. 520 Related circuit diagram................................................................................................... 521 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 522 Related circuit diagram................................................................................................... 523 SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292)................................................................................ 525 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 526 Related circuit diagram................................................................................................... 527 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 528 Related circuit diagram................................................................................................... 529 Fault Code A236: Steering accumulator has not properly bled down after 90 seconds............................................. 530 Related circuit diagram................................................................................................... 531 Fault Code A240: The keyswitch input to the interface module is open.......................................................... 532 Related circuit diagram................................................................................................... 533 Fault Code A246: Payload meter reports truck overload......................................................................... 533 Related circuit diagram................................................................................................... 533 Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted............................... 534 Related circuit diagram................................................................................................... 535 Fault Code A250: Battery voltage is low with the truck parked................................................................. 536 Related circuit diagram................................................................................................... 537 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 538 Related circuit diagram................................................................................................... 539 Fault Code A253: Steering bleed circuit is not open while running............................................................. 540 Related circuit diagram................................................................................................... 541 Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open.................................. 542 Related circuit diagram................................................................................................... 543 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 544 Related circuit diagram................................................................................................... 544 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 546 Related circuit diagram................................................................................................... 547 Fault Code A260: Parking brake failure........................................................................................ 548 Related circuit diagram................................................................................................... 549 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 550 Related circuit diagram................................................................................................... 551 Fault Code A263: Steering bleed circuit is shorted to ground.................................................................. 552 Related circuit diagram................................................................................................... 553 Fault Code A264: Parking brake relay circuit is defective..................................................................... 554 Related circuit diagram................................................................................................... 555 Fault Code A265: Service brake failure........................................................................................ 556 Related circuit diagram................................................................................................... 558 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 560 Related circuit diagram................................................................................................... 561 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 562 Related circuit diagram................................................................................................... 564 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 566 Related circuit diagram................................................................................................... 567 Fault Code A274: A brake setting fault has been detected...................................................................... 568 Related circuit diagram................................................................................................... 569 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 570 Related circuit diagram................................................................................................... 571 Fault Code A276: The drive system data link is not connected.................................................................. 572 Related circuit diagram................................................................................................... 573 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 574 Related circuit diagram................................................................................................... 575 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................... 576 Related circuit diagram................................................................................................... 577 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated...................... 578 Related circuit diagram................................................................................................... 579 Fault Code A285: The parking brake was not set when the key switch was turned off............................................. 580 Related circuit diagram................................................................................................... 581 Fault Code A286: A fault was detected in the shutdown delay relay circuit..................................................... 582 Related circuit diagram................................................................................................... 583 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off......................... 584 Related circuit diagram................................................................................................... 585 SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365)................................................................................ 587 Fault Code A303: Shifter is defective......................................................................................... 588 Related circuit diagram................................................................................................... 589 Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be............ 590 Related circuit diagram................................................................................................... 591 Fault Code A309: No brakes applied when expected.............................................................................. 592 Related circuit diagram................................................................................................... 594 Fault Code A311: Brake lock switch is on when it should not be................................................................ 596 Related circuit diagram................................................................................................... 597 Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings............................................ 598 Related circuit diagram................................................................................................... 598 Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings........................................... 599 Related circuit diagram................................................................................................... 599 Fault Code A315: DC-DC converter 12 volt circuit is low....................................................................... 600 Related circuit diagram................................................................................................... 601 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 602 Related circuit diagram................................................................................................... 603 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 604 Related circuit diagram................................................................................................... 606 Fault Code A318: Unexpected power loss to interface module.................................................................... 607 Related circuit diagram................................................................................................... 607 Fault Code A328: Drive system not powered up.................................................................................. 608 Related circuit diagram................................................................................................... 609 Fault Code A350: Overload on output 1B........................................................................................ 610 Related circuit diagram................................................................................................... 611 Fault Code A351: Overload on output 1E........................................................................................ 612 Related circuit diagram................................................................................................... 613 Fault Code A352: Overload on output 1H........................................................................................ 614 Related circuit diagram................................................................................................... 615 Fault Code A353: Overload on output 1J........................................................................................ 616 Related circuit diagram................................................................................................... 617 Fault Code A354: Overload on output 1K........................................................................................ 618 Related circuit diagram................................................................................................... 619 Fault Code A355: Overload on output 1L........................................................................................ 620 Related circuit diagram................................................................................................... 621 Fault Code A356: Overload on output 1M........................................................................................ 622 Related circuit diagram................................................................................................... 623 Fault Code A357: Overload on output 1N........................................................................................ 624 Related circuit diagram................................................................................................... 625 Fault Code A358: Overload on output 1P........................................................................................ 626 Related circuit diagram................................................................................................... 627 Fault Code A359: Overload on output 1R........................................................................................ 628 Related circuit diagram................................................................................................... 629 Fault Code A360: Overload on output 1S........................................................................................ 630 Related circuit diagram................................................................................................... 631 Fault Code A361: Overload on output 1T........................................................................................ 632 Related circuit diagram................................................................................................... 633 Fault Code A362: Overload on output 1U........................................................................................ 634 Related circuit diagram................................................................................................... 635 Fault Code A363: Overload on output 1X........................................................................................ 636 Related circuit diagram................................................................................................... 636 Fault Code A364: Overload on output 1Y........................................................................................ 638 Related circuit diagram................................................................................................... 639 Fault Code A365: Overload on output 1Z........................................................................................ 640 Related circuit diagram................................................................................................... 641 SECTION G REAR AXLE, SPINDLES AND WHEELS.............................................................................................. 643 SECTION G2 TIRES AND RIMS......................................................................................................... 645 TIRES AND RIMS................................................................................................................ 647 WHEEL STUD MAINTENANCE.................................................................................................... 648 FRONT TIRES AND RIMS...................................................................................................... 649 Removal............................................................................................................... 649 Installation.......................................................................................................... 650 REAR TIRES AND RIMS....................................................................................................... 651 Removal............................................................................................................... 651 Installation.......................................................................................................... 652 RIM....................................................................................................................... 653 Tire Removal.......................................................................................................... 653 Tire Installation..................................................................................................... 653 SECTION G3 FRONT WHEEL HUB AND SPINDLE............................................................................................ 655 FRONT WHEEL HUB AND SPINDLE................................................................................................... 657 WHEEL HUB AND SPINDLE ASSEMBLY............................................................................................ 657 Removal............................................................................................................... 657 Spindle Removal Procedure (off of the truck).......................................................................... 660 Installation.......................................................................................................... 662 Disassembly........................................................................................................... 663 Cleaning and Inspection............................................................................................... 665 Assembly.............................................................................................................. 665 Wheel Bearing Adjustment.............................................................................................. 666 Brake Installation.................................................................................................... 667 Seal Assembly Gap Check............................................................................................... 668 WHEEL SPEED SENSOR TESTING................................................................................................ 669 STEERING CYLINDERS........................................................................................................ 670 Spherical Bearing Wear Limits......................................................................................... 670 Removal............................................................................................................... 671 Installation.......................................................................................................... 671 Bearing Replacement (Steering Cylinder and Tie Rod)................................................................... 671 TIE ROD................................................................................................................... 673 Removal............................................................................................................... 673 Installation.......................................................................................................... 673 Disassembly........................................................................................................... 674 Assembly.............................................................................................................. 674 Toe-In Adjustment..................................................................................................... 675 TIE ROD INSPECTION AND TORQUE PROCEDURE................................................................................... 676 Old Style Tie Rod..................................................................................................... 676 New Style Tie Rod..................................................................................................... 677 SECTION G4 REAR AXLE MOUNTING..................................................................................................... 679 REAR AXLE MOUNTING............................................................................................................ 681 PIVOT PIN................................................................................................................. 681 Removal............................................................................................................... 681 Installation.......................................................................................................... 682 PIVOT EYE BEARING......................................................................................................... 682 Removal............................................................................................................... 682 Installation.......................................................................................................... 682 PIVOT EYE REPAIR.......................................................................................................... 683 Removal............................................................................................................... 683 Installation.......................................................................................................... 683 ANTI-SWAY BAR............................................................................................................. 684 Removal............................................................................................................... 684 Disassembly........................................................................................................... 684 Cleaning and Inspection............................................................................................... 684 Assembly.............................................................................................................. 684 Installation.......................................................................................................... 684 SECTION G5 REAR AXLE AND WHEEL MOTOR.............................................................................................. 687 REAR AXLE AND WHEEL MOTOR..................................................................................................... 689 REAR AXLE HOUSING......................................................................................................... 689 Preparation........................................................................................................... 689 Removal............................................................................................................... 690 Cleaning and Inspection............................................................................................... 691 Installation.......................................................................................................... 691 BLOWER PRESSURE SWITCH ADJUSTMENT......................................................................................... 691 WHEEL MOTOR............................................................................................................... 692 Preparation........................................................................................................... 692 Removal............................................................................................................... 693 Cleaning and Inspection............................................................................................... 695 Installation.......................................................................................................... 695 WHEEL MOTOR GEAR OIL...................................................................................................... 700 Filtering Requirements................................................................................................ 700 Particle Size Analysis................................................................................................ 700 Flushing.............................................................................................................. 700 Oil Sample Analysis................................................................................................... 701 ELEMENT SPECIFICATION CHARTS.............................................................................................. 702 SECTION H HYDRAIR® II SUSPENSIONS..................................................................................................... 705 SECTION H2 FRONT SUSPENSIONS...................................................................................................... 707 FRONT SUSPENSION.............................................................................................................. 709 Removal................................................................................................................... 709 Installation.............................................................................................................. 710 Inspection................................................................................................................ 715 LOWER BEARING & SEALS..................................................................................................... 716 Removal............................................................................................................... 716 Installation.......................................................................................................... 716 MAJOR SUSPENSION REBUILD.................................................................................................. 717 Disassembly........................................................................................................... 717 Assembly.............................................................................................................. 718 SUSPENSION PRESSURE TEST.................................................................................................. 719 SECTION H3 REAR SUSPENSIONS....................................................................................................... 721 REAR SUSPENSIONS.............................................................................................................. 723 SUSPENSION CYLINDER....................................................................................................... 724 Removal............................................................................................................... 724 Installation.......................................................................................................... 726 Disassembly........................................................................................................... 726 Cleaning and Inspection............................................................................................... 727 Assembly.............................................................................................................. 727 SUSPENSION PRESSURE TEST.................................................................................................. 729 SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES.............................................................................. 731 SUSPENSION OILING AND CHARGING PROCEDURE...................................................................................... 733 GENERAL................................................................................................................... 733 EQUIPMENT LIST............................................................................................................ 733 HYDRAIR® CHARGING KIT..................................................................................................... 734 Installation of Charging Kit.......................................................................................... 734 Removal of Charging Kit............................................................................................... 734 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS......................................................................... 735 FRONT SUSPENSION.......................................................................................................... 735 Front Suspension Oiling............................................................................................... 735 Front Suspension Nitrogen Charging.................................................................................... 737 REAR SUSPENSION........................................................................................................... 738 Rear Suspension Oiling................................................................................................ 739 Rear Suspension Nitrogen Charging..................................................................................... 741 OIL AND NITROGEN SPECIFICATIONS CHARTS........................................................................................ 742 SECTION J BRAKE CIRCUIT............................................................................................................... 743 SECTION J2 BRAKE CIRCUIT.......................................................................................................... 745 BRAKE CIRCUIT................................................................................................................. 747 SERVICE BRAKE CIRCUIT..................................................................................................... 747 PARKING BRAKE CIRCUIT..................................................................................................... 749 BRAKE LOCK CIRCUIT........................................................................................................ 749 SECONDARY BRAKING AND AUTOMATIC APPLY..................................................................................... 750 WARNING CIRCUIT........................................................................................................... 750 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE........................................................................................ 753 BRAKE CIRCUIT COMPONENT SERVICE............................................................................................... 755 BRAKE VALVE............................................................................................................... 755 Rebuild Criteria...................................................................................................... 755 Removal............................................................................................................... 756 Installation.......................................................................................................... 756 Disassembly........................................................................................................... 757 Cleaning and Inspection............................................................................................... 760 Assembly.............................................................................................................. 760 Regulator Sleeve O-Ring Installation.................................................................................. 761 BRAKE VALVE BENCH TEST AND ADJUSTMENT..................................................................................... 763 Test Setup Procedure.................................................................................................. 764 Brake Valve Output Pressure Adjustment................................................................................ 764 Final Test and Adjustment............................................................................................. 765 Installing Brake Pedal Actuator Assembly to Brake Valve............................................................... 765 Installing Retard Pedal To Brake Pedal................................................................................ 765 DUAL RELAY VALVE.......................................................................................................... 766 Removal............................................................................................................... 766 Installation.......................................................................................................... 766 Disassembly........................................................................................................... 766 Cleaning and Inspection............................................................................................... 767 Assembly.............................................................................................................. 768 DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT................................................................................ 769 Test Setup Procedure.................................................................................................. 770 Relay Valve Output Pressure Adjustment................................................................................ 770 BRAKE MANIFOLD............................................................................................................ 771 Removal............................................................................................................... 771 Installation.......................................................................................................... 771 Disassembly........................................................................................................... 771 Cleaning and Inspection............................................................................................... 772 Assembly.............................................................................................................. 772 BRAKE ACCUMULATORS........................................................................................................ 772 Brake Accumulator Bleeddown Procedure................................................................................. 772 Removal............................................................................................................... 773 Installation.......................................................................................................... 773 Disassembly........................................................................................................... 774 Cleaning and Inspection............................................................................................... 775 Assembly.............................................................................................................. 775 Accumulator Charging Procedure........................................................................................ 777 Precharge Maintenance................................................................................................. 779 Accumulator Storage Procedures........................................................................................ 780 Bladder Storage Procedures............................................................................................ 780 Installing A Bladder Accumulator From Storage......................................................................... 780 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................................................... 781 Removal............................................................................................................... 781 Installation.......................................................................................................... 781 Disassembly........................................................................................................... 781 Lever Adjustments..................................................................................................... 781 Potentiometer Check................................................................................................... 782 Assembly.............................................................................................................. 782 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE...................................................................................... 785 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................................................. 787 REQUIRED EQUIPMENT........................................................................................................ 788 INITIAL SYSTEM SETUP...................................................................................................... 789 BRAKE LOCK / SECONDARY BRAKE CHECK-OUT.................................................................................... 790 PARKING BRAKE CHECK-OUT................................................................................................... 791 SERVICE BRAKE CHECK-OUT................................................................................................... 792 LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT......................................................................... 793 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART........................................................................... 794 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET......................................................................... 796 SECTION J5 WET DISC BRAKE ASSEMBLY................................................................................................ 799 WET DISC BRAKE ASSEMBLY....................................................................................................... 801 OPERATION................................................................................................................. 801 BRAKE DISC WEAR INSPECTION................................................................................................ 802 BRAKE REBUILD............................................................................................................. 803 Disassembly........................................................................................................... 803 Cleaning and Inspection............................................................................................... 807 Assembly.............................................................................................................. 808 Floating Ring Seal Assembly & Installation............................................................................ 813 WET DISC BRAKE BLEEDING PROCEDURE......................................................................................... 817 SECTION J7 PARKING BRAKE.......................................................................................................... 819 PARKING BRAKE................................................................................................................. 821 OPERATION................................................................................................................. 821 MAINTENANCE............................................................................................................... 822 Inspection............................................................................................................ 822 Removal............................................................................................................... 822 Installation.......................................................................................................... 823 Disassembly........................................................................................................... 823 Cleaning and Inspection............................................................................................... 823 Assembly.............................................................................................................. 825 Cleaning and Inspecting New Discs..................................................................................... 826 PARKING BRAKE BLEEDING PROCEDURE.......................................................................................... 827 SECTION L HYDRAULIC SYSTEM............................................................................................................ 829 SECTION L2 HYDRAULIC SYSTEM....................................................................................................... 831 HYDRAULIC SYSTEM.............................................................................................................. 833 HYDRAULIC PUMP MODULE..................................................................................................... 833 HOIST CIRCUIT OPERATION................................................................................................... 834 STEERING CIRCUIT OPERATION................................................................................................ 836 DISC BRAKE COOLING SYSTEM................................................................................................. 838 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR...................................................................................... 841 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................................................. 843 HOIST PUMP................................................................................................................ 843 Removal............................................................................................................... 843 Installation.......................................................................................................... 845 Inspection............................................................................................................ 850 Assembly.............................................................................................................. 850 HYDRAULIC TANK............................................................................................................ 856 Removal............................................................................................................... 856 Installation.......................................................................................................... 857 HYDRAULIC TANK BREATHERS.................................................................................................. 857 HYDRAULIC TANK STRAINERS.................................................................................................. 858 Removal............................................................................................................... 858 Inspect and Clean..................................................................................................... 858 Installation.......................................................................................................... 858 SECTION L4 STEERING CIRCUIT....................................................................................................... 859 STEERING CIRCUIT.............................................................................................................. 861 STEERING CIRCUIT OPERATION................................................................................................ 861 COMPONENT DESCRIPTION..................................................................................................... 862 Steering Control Unit................................................................................................. 862 Bleeddown Manifold.................................................................................................... 863 Steering Accumulator Bleed Down Solenoid.............................................................................. 863 Relief Valves......................................................................................................... 865 Hoist Up Limit Solenoid............................................................................................... 865 Steering Accumulators................................................................................................. 865 Low Precharge Warning Switch.......................................................................................... 865 High Pressure Filter.................................................................................................. 865 Quick Disconnect Ports................................................................................................ 865 Flow Amplifier........................................................................................................ 867 FLOW AMPLIFIER SYSTEM OPERATION........................................................................................... 868 No Steer.............................................................................................................. 868 Steering Left......................................................................................................... 870 Steering Right........................................................................................................ 872 No Steer, External Shock Load......................................................................................... 874 STEERING PUMP............................................................................................................. 876 Normal Operation...................................................................................................... 876 PRINCIPLE OF OPERATION.................................................................................................... 878 Full Pump Volume...................................................................................................... 878 Half Pump Volume...................................................................................................... 878 Neutral Position...................................................................................................... 878 Steering Pump......................................................................................................... 879 SECTION L5 STEERING CONTROL UNIT.................................................................................................. 881 STEERING CONTROL UNIT......................................................................................................... 883 REMOVAL................................................................................................................... 883 SPLINE INSPECTION......................................................................................................... 883 INSTALLATION.............................................................................................................. 884 DISASSEMBLY............................................................................................................... 884 CLEANING AND INSPECTION................................................................................................... 885 ASSEMBLY.................................................................................................................. 887 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR...................................................................................... 891 STEERING CIRCUIT COMPONENT REPAIR............................................................................................. 893 BLEEDDOWN MANIFOLD VALVE.................................................................................................. 893 Removal............................................................................................................... 893 Installation.......................................................................................................... 894 FLOW AMPLIFIER............................................................................................................ 895 Removal............................................................................................................... 895 Installation.......................................................................................................... 895 Disassembly........................................................................................................... 895 Assembly.............................................................................................................. 897 STEERING CYLINDERS........................................................................................................ 898 Disassembly........................................................................................................... 899 Piston Seal & Bearing Installation.................................................................................... 899 Assembly.............................................................................................................. 899 Testing............................................................................................................... 899 STEERING AND BRAKE PUMP................................................................................................... 900 Removal............................................................................................................... 900 Installation.......................................................................................................... 901 Disassembly........................................................................................................... 902 Inspection............................................................................................................ 905 Assembly.............................................................................................................. 908 Driveshaft Group...................................................................................................... 909 Rotating Group........................................................................................................ 909 Valve Plate Group..................................................................................................... 910 STEERING ACCUMULATORS..................................................................................................... 912 Removal............................................................................................................... 912 Installation.......................................................................................................... 912 Disassembly........................................................................................................... 913 Cleaning and Inspection............................................................................................... 913 Assembly.............................................................................................................. 914 Leak Testing.......................................................................................................... 916 Charging Procedure.................................................................................................... 917 Precharge Maintenance................................................................................................. 919 Accumulator Storage Procedures........................................................................................ 920 Bladder Storage Procedures............................................................................................ 920 Installing A Bladder Accumulator From Storage......................................................................... 920 TROUBLESHOOTING............................................................................................................... 921 STEERING CIRCUIT.......................................................................................................... 921 STEERING PUMP............................................................................................................. 923 Basic Hydraulic System Checks......................................................................................... 924 System Leakage Check.................................................................................................. 925 Steering Pump Troubleshooting Guide................................................................................... 927 Pump Pressure Control Checks.......................................................................................... 930 Pump Fails to Unload.................................................................................................. 931 Pump Fails to Develop Pressure........................................................................................ 931 Pump Slow in Developing Pressure...................................................................................... 932 Pump Control Valve Inspection and Troubleshooting..................................................................... 933 Pump Case Drain Check................................................................................................. 933 Setting Pump Pressure Controls........................................................................................ 935 Adjustment............................................................................................................ 936 SECTION L7 HOIST CIRCUIT.......................................................................................................... 937 HOIST CIRCUIT................................................................................................................. 939 BASIC OPERATION........................................................................................................... 939 COMPONENT DESCRIPTION..................................................................................................... 940 Hydraulic Tank........................................................................................................ 940 Hydraulic Pump........................................................................................................ 940 High Pressure Filters................................................................................................. 940 Hoist Valve........................................................................................................... 940 Inlet Sections........................................................................................................ 940 Work Ports (Rear) Spool Section....................................................................................... 941 Tank Ports (Front) Spool Section...................................................................................... 941 Hoist Pilot Valve..................................................................................................... 941 Bleeddown Manifold.................................................................................................... 942 Hoist Up Limit Solenoid............................................................................................... 942 Pilot Operated Check Valve............................................................................................ 942 Overcenter Manifold................................................................................................... 942 HOIST CIRCUIT OPERATION....................................................................................................... 943 Float Position Of Pilot Valve With Truck Body On Frame.................................................................... 944 Power Up Operation........................................................................................................ 946 Hold Operation............................................................................................................ 948 Power Down Operation...................................................................................................... 950 Float Operation........................................................................................................... 952 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR......................................................................................... 955 HOIST CIRCUIT COMPONENT REPAIR................................................................................................ 957 HOIST VALVE............................................................................................................... 957 Removal............................................................................................................... 957 Installation.......................................................................................................... 958 O-Ring Replacement.................................................................................................... 958 INLET SECTION............................................................................................................. 959 Disassembly........................................................................................................... 959 Cleaning and Inspection............................................................................................... 960 Assembly.............................................................................................................. 960 REAR SPOOL SECTION (Work Ports)........................................................................................... 961 Disassembly........................................................................................................... 961 Cleaning and Inspection............................................................................................... 961 Assembly.............................................................................................................. 963 FRONT SPOOL SECTION (Tank Ports).......................................................................................... 964 Disassembly........................................................................................................... 964 Cleaning and Inspection............................................................................................... 964 Assembly.............................................................................................................. 964 HOIST PILOT VALVE......................................................................................................... 966 Removal............................................................................................................... 966 Installation.......................................................................................................... 966 Disassembly........................................................................................................... 967 Cleaning and Inspection............................................................................................... 968 Assembly.............................................................................................................. 968 HOIST CYLINDERS........................................................................................................... 969 Removal............................................................................................................... 969 Installation.......................................................................................................... 970 Disassembly........................................................................................................... 972 Cleaning and Inspection............................................................................................... 973 Assembly - Quill...................................................................................................... 974 Assembly - Cylinder................................................................................................... 976 Testing............................................................................................................... 976 OVERCENTER VALVE MANIFOLD................................................................................................. 977 SECTION L9 HYDRAULIC SYSTEM FILTERS............................................................................................... 979 HYDRAULIC SYSTEM FILTERS...................................................................................................... 981 HOIST CIRCUIT FILTER...................................................................................................... 981 Filter Element Replacement............................................................................................ 981 Removal - Hoist Circuit Filter........................................................................................ 982 Installation - Hoist Circuit Filter................................................................................... 982 Indicator Switch - Hoist Circuit Filter............................................................................... 982 STEERING CIRCUIT FILTER................................................................................................... 983 Filter Element Replacement............................................................................................ 983 Removal - Steering Circuit Filter..................................................................................... 984 Installation - Steering Circuit Filter................................................................................ 984 Indicator Switch - Steering Circuit Filter............................................................................ 984 INDICATOR SWITCH.......................................................................................................... 984 Test Procedure........................................................................................................ 984 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE.......................................................................................... 987 HYDRAULIC CHECKOUT PROCEDURE.................................................................................................. 989 GENERAL INFORMATION....................................................................................................... 989 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................................................... 996 Equipment Requirements................................................................................................ 997 Pump Pressure Control Adjustments..................................................................................... 997 Steering Control Valve and Flow Amplifier Leakage Test................................................................ 998 Bleeddown Manifold Leakage Test....................................................................................... 999 STEERING/BRAKE PUMP STROKE ADJUSTMENT.....................................................................................1000 SHOCK AND SUCTION VALVES..................................................................................................1000 Equipment Requirements................................................................................................1000 Pressure Tests........................................................................................................1000 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.............................................................1002 Equipment Requirements................................................................................................1002 Pressure Gauge Locations..............................................................................................1002 Brake Cooling Circuit Test............................................................................................1002 Power Up Relief Pressure Test.........................................................................................1003 Power Down Relief Pressure Test.......................................................................................1004 Counterbalance Valve Pressure Check...................................................................................1005 Counterbalance Valve Adjustment.......................................................................................1006 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET.........................................................................1007 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET............................................................1008 SECTION M OPTIONS AND SPECIAL TOOLS...................................................................................................1009 SECTION M7 HOT START SYSTEM.......................................................................................................1011 HOT START SYSTEM..............................................................................................................1013 SYSTEM OPERATION..........................................................................................................1013 HEATER INFORMATION........................................................................................................1014 TROUBLESHOOTING GUIDELINES................................................................................................1015 SECTION M8 SPECIAL TOOLS..........................................................................................................1017 HIGH VOLTAGE TOOLS............................................................................................................1021 0-2000 VDC CUSTOM METER KIT (58B-06-00800)....................................................................................1021 SECTION M19 RADIATOR SHUTTERS.....................................................................................................1025 RADIATOR SHUTTERS.............................................................................................................1027 OPERATION.................................................................................................................1027 Hydraulic Circuit.....................................................................................................1027 Electrical Circuit....................................................................................................1028 MAINTENANCE AND REPAIR....................................................................................................1028 TROUBLESHOOTING...........................................................................................................1029 SECTION M20 PAYLOAD METER III ™...................................................................................................1033 OPERATION SECTION.............................................................................................................1037 Introduction..............................................................................................................1037 Data Summary..........................................................................................................1037 Data Gathering........................................................................................................1037 COMPONENT DESCRIPTION.....................................................................................................1038 System Diagram........................................................................................................1038 Suspension Pressure Sensors...........................................................................................1038 Inclinometer..........................................................................................................1038 Operator Display......................................................................................................1038 Operator Switch.......................................................................................................1039 Speed Input...........................................................................................................1039 Body-Up Switch........................................................................................................1039 Brake Lock Switch.....................................................................................................1039 Payload Meter.........................................................................................................1039 Communications Ports..................................................................................................1039 Key Switch Input......................................................................................................1040 Payload Meter Power...................................................................................................1040 Load Lights...........................................................................................................1040 Wiring and Termination................................................................................................1041 TCI Outputs...........................................................................................................1041 OPERATOR’S DISPLAY AND SWITCH.............................................................................................1042 Reading the Speedometer...............................................................................................1042 Reading the Load Display..............................................................................................1042 Using the Operator ID.................................................................................................1042 Using the Load and Ton Counter........................................................................................1042 Total Ton Counter.....................................................................................................1042 Total Load Counter....................................................................................................1043 Clearing the Counters.................................................................................................1043 Viewing Live Sensor Data..............................................................................................1043 Other Display Messages................................................................................................1043 PAYLOAD OPERATION & CALCULATION...........................................................................................1044 Description of Haul Cycle States......................................................................................1044 Haul Cycle Description................................................................................................1044 Load Calculation......................................................................................................1045 Carry Back............................................................................................................1045 Measurement Accuracy..................................................................................................1045 SOURCES FOR PAYLOAD ERROR.................................................................................................1045 Payload Error.........................................................................................................1045 Loading Conditions....................................................................................................1046 Pressure Sensors......................................................................................................1046 Swingloads............................................................................................................1046 Speed and Distance....................................................................................................1046 HAUL CYCLE DATA...........................................................................................................1046 Haul Cycle Warning Flags..............................................................................................1048 Frame Torque Data.....................................................................................................1049 Sprung Weight Data....................................................................................................1049 Maximum Speed Data....................................................................................................1049 Alarm Records.........................................................................................................1049 Fault Code Data.......................................................................................................1050 PC SOFTWARE OVERVIEW......................................................................................................1051 System Configuration..................................................................................................1051 Installing the PLMIII Software........................................................................................1051 DOWNLOADING DATA..........................................................................................................1052 PLM III SYSTEM CONFIGURATION..............................................................................................1053 Starting Communications...............................................................................................1053 Displayed Payload Units...............................................................................................1053 Time Units............................................................................................................1053 Connection Menu.......................................................................................................1053 Connecting to the Payload Meter.......................................................................................1054 Configure the Payload Meter...........................................................................................1054 Setting the Date and Time.............................................................................................1054 Setting the Truck Type................................................................................................1055 Setting the Gauge Display Units.......................................................................................1055 Setting the Frame Serial Number.......................................................................................1055 Setting the Truck Number..............................................................................................1055 Setting the Komatsu Distributor.......................................................................................1055 Setting the Komatsu Customer..........................................................................................1055 Clean Truck Tare Calibration..........................................................................................1056 Inclinometer Calibration..............................................................................................1056 DATA ANALYSIS.............................................................................................................1057 Creating a Query......................................................................................................1057 Sorting on Truck Unit Number..........................................................................................1057 Sorting on Truck Type.................................................................................................1057 Sorting on Date Range.................................................................................................1058 Sorting on Time Range.................................................................................................1058 Payload Detail Screen.................................................................................................1059 Creating Reports......................................................................................................1059 Summary - one page report.............................................................................................1060 Detailed - multi-page report..........................................................................................1060 Creating Graphs.......................................................................................................1061 Exporting Data........................................................................................................1061 CSV Export............................................................................................................1061 Compressed............................................................................................................1062 Importing Data........................................................................................................1063 Deleting Haul Cycle Records...........................................................................................1063 Viewing Alarms........................................................................................................1064 Deleting Alarm Records................................................................................................1064 TROUBLESHOOTING SECTION.......................................................................................................1065 TROUBLESHOOTING...........................................................................................................1065 Viewing Active Alarms.................................................................................................1065 Real-Time Data Display................................................................................................1065 Testing the Payload Lights............................................................................................1065 Creating Log Files of Inputs..........................................................................................1066 Daily Inspections.....................................................................................................1066 Periodic Maintenance..................................................................................................1066 Abnormal Displays at Power-Up.........................................................................................1067 No Payload Display When Key Switch is Turned ON.......................................................................1068 No Display on Speedometer.............................................................................................1069 No Display on Operator Display........................................................................................1069 No Communications With PC.............................................................................................1070 Load Lights Don’t Light During Loading................................................................................1071 Load Lights Remain ON.................................................................................................1072 Load Lights Remain ON During Dumping..................................................................................1072 Display Doesn't Clear When The Load Is Dumped.........................................................................1072 Calibration Problems..................................................................................................1073 Alarm 1 - Left Front Pressure High....................................................................................1074 Alarm 2 - Left Front Pressure Low.....................................................................................1074 Troubleshoot Wiring to Left Front Suspension..........................................................................1074 Alarm 3 - Right Front Pressure High...................................................................................1075 Alarm 4 - Right Front Pressure Low....................................................................................1075 Troubleshoot Wiring to Right Front Suspension.........................................................................1075 Alarm 5 -Left Rear Pressure High......................................................................................1076 Alarm 6 - Left Rear Pressure Low......................................................................................1076 Troubleshoot Wiring to Left Rear Suspension...........................................................................1076 Alarm 7 - Right Rear Pressure High....................................................................................1077 Alarm 8 - Right Rear Pressure Low.....................................................................................1077 Troubleshoot Wiring to Right Rear Suspension..........................................................................1077 Alarm 9 - Inclinometer High...........................................................................................1078 Alarm 10 - Inclinometer Low...........................................................................................1078 Troubleshoot Inclinometer Wiring......................................................................................1078 Alarm 13 - Body Up Input Failure......................................................................................1079 Alarm 16 - Memory Write Failure.......................................................................................1080 Alarm 17 - Memory Read Failure........................................................................................1080 Alarm 18..............................................................................................................1081 Alarm 19..............................................................................................................1081 Alarm 22..............................................................................................................1081 Operator Switch Doesn't Work..........................................................................................1082 Alarm 26 - User Switch Fault - SELECT.................................................................................1082 Alarm 27 - User Switch Fault - SET....................................................................................1082 Connector Map.........................................................................................................1083 Connectors............................................................................................................1084 PLMIII CHECK OUT PROCEDURE....................................................................................................1085 General Description.......................................................................................................1085 Tools Required............................................................................................................1085 Checkout Procedure........................................................................................................1085 PLMIII CHECKOUT PROCEDURE CONFIRMATION....................................................................................1089 Flashburn Programming.................................................................................................1089 Confirmation Checklist................................................................................................1091 SECTION M31 RESERVE ENGINE OIL SYSTEM.............................................................................................1093 RESERVE ENGINE OIL SYSTEM.....................................................................................................1095 Operation.................................................................................................................1096 LED Monitor Light.........................................................................................................1096 Tank Fill Control (Optional)..............................................................................................1097 Filling Procedure (Remote Fill Feature)...................................................................................1097 SERVICE...................................................................................................................1098 Every 10 Hours, or once each shift:...................................................................................1098 Every 500 Hours.......................................................................................................1098 Changing Oil..........................................................................................................1098 TROUBLESHOOTING...........................................................................................................1099 Circuit Fuse..........................................................................................................1099 SYSTEM ELECTRICAL SCHEMATICS..............................................................................................1100 SECTION M32 RETRACTABLE LADDER SYSTEM.............................................................................................1101 RETRACTABLE LADDER SYSTEM.....................................................................................................1106 GENERAL SAFETY............................................................................................................1106 LADDER SYSTEM DESCRIPTION.................................................................................................1106 LADDER SYSTEM OPERATION...................................................................................................1106 Normal Operation......................................................................................................1106 Emergency Operation...................................................................................................1108 Limit Switch Operation................................................................................................1108 IN-CAB CONTROL PANEL......................................................................................................1108 IN-CAB CONTROL PANEL FEATURES.............................................................................................1110 Digital Display Screen................................................................................................1110 Command Buttons.......................................................................................................1110 IN-CAB CONTROL PANEL FUNCTIONS............................................................................................1112 Timing Control........................................................................................................1112 Ladder System Status..................................................................................................1112 Fault Code Identification.............................................................................................1112 Ladder System Configuration...........................................................................................1113 In-Cab Control Panel Lockout..........................................................................................1113 Automatic Raising.....................................................................................................1113 Diagnostics...........................................................................................................1113 Maintenance...........................................................................................................1113 USING THE IN-CAB CONTROL PANEL............................................................................................1114 Raising the Ladder....................................................................................................1114 Lowering the Ladder...................................................................................................1115 USING THE GROUND LEVEL CONTROL BOX........................................................................................1116 Raising the Ladder....................................................................................................1116 Lowering the Ladder...................................................................................................1116 POWER PACK OPERATION......................................................................................................1117 MAINTENANCE...............................................................................................................1121 Safety During Maintenance.............................................................................................1121 Unplanned Ladder Movements............................................................................................1121 Automatic Ladder Raising..............................................................................................1121 Automatic Accumulator Recharging (Ladder in UP position)..............................................................1122 PREVENTIVE MAINTENANCE PROCEDURES.........................................................................................1123 Daily Inspection......................................................................................................1123 250 Hour Inspection...................................................................................................1123 5000 Hour Inspection..................................................................................................1123 SERVICING.................................................................................................................1124 Check Reservoir Oil Level.............................................................................................1124 Changing RLS Fluid....................................................................................................1124 Cleaning the RLS......................................................................................................1125 RLS DIAGNOSTICS...........................................................................................................1125 Description of Diagnostics Features...................................................................................1125 Continuous System Monitoring..........................................................................................1126 Historic System Data Review...........................................................................................1127 Comms Integrity Monitoring............................................................................................1127 Log and Service Information...........................................................................................1127 System Event Logs.....................................................................................................1128 SECURITY ACCESS LEVELS....................................................................................................1129 Access Level 1 – NONE.................................................................................................1129 Access Level 2 – RESTRICTED...........................................................................................1129 Access Level 3 – COMPLETE.............................................................................................1129 User Access Privileges................................................................................................1130 USER ID – PASSWORD........................................................................................................1131 Sequential Field Value Selection Options..............................................................................1131 Password Character Table..............................................................................................1131 USER ID – NEW USER SETUP..................................................................................................1132 SYSTEM FAULTS.............................................................................................................1132 Fault Type 1: Communications error....................................................................................1133 Fault Type 2: 10A/15A fuse blown......................................................................................1133 Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected.............................................1134 Fault Type 8: Power pack recharge too long............................................................................1134 Fault Type 9: Inhibit relay fail......................................................................................1135 Fault Types 10, 11: Light/Siren relay failure.........................................................................1135 Fault Type 12: Ladder came off upper limit............................................................................1136 Fault Type 13: Ladder did not reach limit.............................................................................1136 Fault Type 14: Ladder stayed on limit.................................................................................1137 Fault Type 15: Low oil level..........................................................................................1137 Fault Type 16: System voltage over 18V during movement................................................................1138 Fault Type 17: System voltage under 18V...............................................................................1138 Fault Type 18: System voltage over 31V................................................................................1139 Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped)........................................1139 Fault Type 21: Accumulator recharge > than once/hour..................................................................1140 Fault Type 22: System raised by park brake............................................................................1140 Fault Types 23, 24: Levels 1 and 2 service overdue....................................................................1141 Fault Type 25: Levels 1 and 2 service complete........................................................................1141 DATA MANAGEMENT...........................................................................................................1142 Log Files.............................................................................................................1142 Generating Reports....................................................................................................1143 MENU DIAGRAMS.............................................................................................................1149 Controller Config.....................................................................................................1149 Contact Information...................................................................................................1149 Show Recent Logs......................................................................................................1149 System Settings.......................................................................................................1149 Upload Logs to USB....................................................................................................1149 Diagnostics...........................................................................................................1149 SECTION M33 CAMERA SYSTEM.........................................................................................................1157 CAMERA SYSTEM.................................................................................................................1158 CAMERA SYSTEM.............................................................................................................1158 General...............................................................................................................1158 Operation.............................................................................................................1158 Camera Switch.........................................................................................................1159 CAMERA MONITOR............................................................................................................1160 General...............................................................................................................1160 CAMERA CONTROLLER.........................................................................................................1161 General...............................................................................................................1161 Removal...............................................................................................................1161 Installation..........................................................................................................1161 Camera Controller Connector Pins......................................................................................1161 CAMERA SWITCHER...........................................................................................................1162 General...............................................................................................................1162 Removal...............................................................................................................1162 Installation..........................................................................................................1162 SETUP AND CHECKOUT PROCEDURE..............................................................................................1163 General...............................................................................................................1163 STEP 1 - Switch Function..............................................................................................1163 STEP 2 - Monitor System Settings to Default...........................................................................1163 STEP 4 - Monitor Settings - System Settings Unique....................................................................1165 STEP 4 - Monitor Settings - System Settings Unique - Cameras..........................................................1167 STEP 5 - Monitor Settings - System Settings Unique - On Screen Delay..................................................1169 STEP 6 - Monitor Settings - System Settings Unique - Standby Mode.....................................................1170 STEP 7 - Integrated Functions Check...................................................................................1171 SECTION N OPERATOR CAB................................................................................................................1173 SECTION N2 TRUCK CAB AND COMPONENTS...............................................................................................1175 TRUCK CAB AND COMPONENTS......................................................................................................1177 TRUCK CAB.................................................................................................................1177 Description...........................................................................................................1177 Removal...............................................................................................................1178 Installation..........................................................................................................1179 CAB DOOR..................................................................................................................1180 Removal...............................................................................................................1180 Installation..........................................................................................................1180 Door Jamb Bolt Adjustment.............................................................................................1181 Door Handle Plunger Adjustment........................................................................................1182 Replacing the Door Glass..............................................................................................1183 Replacing the Door Handle or Latch Assembly...........................................................................1187 Replacing the Door Window Regulator...................................................................................1188 Replacing the Door and Door Hinge Seal................................................................................1189 Replacing the Door Opening Seal.......................................................................................1189 GLASS REPLACEMENT (Adhesive-Bonded Windows)...............................................................................1190 Recommended Tools and Supplies........................................................................................1190 Replacement Procedure.................................................................................................1190 WINDSHIELD AND REAR GLASS.................................................................................................1191 Removal...............................................................................................................1191 Installation..........................................................................................................1192 SECTION N3 CAB COMPONENTS.........................................................................................................1193 CAB COMPONENTS................................................................................................................1195 WINDSHIELD WIPERS.........................................................................................................1195 WIPER MOTOR...........................................................................................................1195 Removal...........................................................................................................1195 Installation......................................................................................................1195 WIPER ARM.............................................................................................................1195 Removal...........................................................................................................1195 Installation......................................................................................................1196 WIPER LINKAGE.........................................................................................................1196 Removal...........................................................................................................1196 Installation......................................................................................................1196 WINDSHIELD WASHER.........................................................................................................1197 Operation.............................................................................................................1197 Service...............................................................................................................1197 OPERATOR SEAT (STANDARD SEAT).............................................................................................1198 Adjustment............................................................................................................1198 Inspection............................................................................................................1199 Removal...............................................................................................................1199 Installation..........................................................................................................1199 Replacing the Seat Compressor.........................................................................................1200 PASSENGER SEAT (STANDARD SEAT)............................................................................................1205 Inspection............................................................................................................1205 Removal...............................................................................................................1205 Installation..........................................................................................................1205 SEAT BELT REPLACEMENT (STANDARD SEATS - PC3230)...........................................................................1206 Removal...............................................................................................................1206 Installation..........................................................................................................1206 SEAT BELT REPLACEMENT (STANDARD SEATS - 58E-57-00500).....................................................................1208 Removal...............................................................................................................1208 Installation..........................................................................................................1208 OPERATOR SEAT (OPTIONAL SEAT).........................................................................................1210 Seat Belts........................................................................................................1210 Adjustment........................................................................................................1210 PASSENGER SEAT (OPTIONAL SEAT)........................................................................................1211 Seat Belts........................................................................................................1211 Adjustment........................................................................................................1211 SEAT BELT REPLACEMENT (OPTIONAL SEATS)....................................................................................1212 General...............................................................................................................1212 Removal...............................................................................................................1212 SECTION N4 HEATER / AIR CONDITIONER...............................................................................................1217 HEATER/AIR CONDITIONER........................................................................................................1219 OPERATION.................................................................................................................1219 Fan Speed Control Knob................................................................................................1219 Temperature Control Knob..............................................................................................1219 Air Flow Directional Knob.............................................................................................1220 Heater/Air Conditioner Vents..........................................................................................1220 COMPONENTS................................................................................................................1220 Fuse and Circuit Breaker..............................................................................................1220 Relays................................................................................................................1220 Heater Core...........................................................................................................1221 Fan Motor And Speed Control...........................................................................................1221 Actuators.............................................................................................................1221 Cab Air Filter........................................................................................................1221 ENVIRONMENTAL IMPACT OF AIR CONDITIONING..................................................................................1224 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.................................................................................1224 PRINCIPLES OF REFRIGERATION...............................................................................................1224 Air Conditioning......................................................................................................1224 Refrigeration - The Act Of Cooling....................................................................................1225 The Refrigeration Cycle...............................................................................................1225 AIR CONDITIONER SYSTEM COMPONENTS.........................................................................................1226 Compressor (Refrigerant Pump).........................................................................................1226 Service Valves........................................................................................................1226 Condenser.............................................................................................................1226 Receiver-Drier........................................................................................................1226 Expansion Block Valve.................................................................................................1227 Accumulator...........................................................................................................1227 Evaporator............................................................................................................1227 ELECTRICAL CIRCUIT........................................................................................................1228 Thermostat............................................................................................................1228 Compressor Clutch.....................................................................................................1228 Trinary™ Switch.......................................................................................................1229 AIR CONDITIONING SYSTEM SERVICING WARNINGS................................................................................1230 SERVICE TOOLS AND EQUIPMENT...............................................................................................1231 Recovery/Recycle Station..............................................................................................1231 Leak Detector.........................................................................................................1231 Manifold Gauge Set....................................................................................................1232 Installing Manifold Gauge Set.........................................................................................1233 Purging Air From Service Hoses........................................................................................1233 Service Valves........................................................................................................1234 Vacuum Pump...........................................................................................................1234 SYSTEM PERFORMANCE TEST...................................................................................................1235 SYSTEM OIL................................................................................................................1236 Handling and Reusing PAG Oil..........................................................................................1236 Oil Quantity..........................................................................................................1236 Checking System Oil...................................................................................................1236 REFRIGERANT...............................................................................................................1237 Recycled Refrigerant..................................................................................................1237 Reclaimed Refrigerant.................................................................................................1237 Refrigerant Quantity..................................................................................................1238 R-134a Refrigerant Containers.........................................................................................1238 SYSTEM LEAK TESTING.......................................................................................................1238 Electronic Leak Detector..............................................................................................1239 Tracer Dyes...........................................................................................................1239 Soap and Water........................................................................................................1239 RECOVERING AND RECYCLING THE REFRIGERANT..................................................................................1239 Draining Oil from the Previous Recovery Cycle.........................................................................1239 Performing the Recovery Cycle.........................................................................................1239 Performing the Recycling Procedure....................................................................................1240 Evacuating and Charging the A/C System................................................................................1240 SYSTEM REPAIR.............................................................................................................1240 System Flushing.......................................................................................................1240 COMPONENT REPLACEMENT.....................................................................................................1241 Hoses and Fittings....................................................................................................1241 Lines.................................................................................................................1241 Expansion Valve.......................................................................................................1241 Receiver-Drier........................................................................................................1241 Thermostat............................................................................................................1241 Compressor............................................................................................................1242 Accumulator...........................................................................................................1242 Clutch................................................................................................................1242 EVACUATING THE SYSTEM.....................................................................................................1243 CHARGING THE A/C SYSTEM...................................................................................................1244 TROUBLESHOOTING...........................................................................................................1245 Preliminary Checks....................................................................................................1245 Diagnosis Of Gauge Readings And System Performance....................................................................1245 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................................................................1246 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM................................................................................1252 SECTION N5 OPERATOR CAB AND CONTROLS..............................................................................................1253 OPERATOR CAB AND CONTROLS.....................................................................................................1256 STEERING COLUMN...........................................................................................................1257 Removal...............................................................................................................1257 Inspection............................................................................................................1257 Installation..........................................................................................................1258 STEERING WHEEL............................................................................................................1258 Removal...............................................................................................................1258 Installation..........................................................................................................1258 STEERING WHEEL AND CONTROLS...............................................................................................1260 Horn Button...........................................................................................................1260 Tilt / Telescope Lever................................................................................................1260 Multi-Function Turn Signal Switch.....................................................................................1260 DYNAMIC RETARDING.........................................................................................................1261 Retarder Lever........................................................................................................1261 Brake/Retarder Pedal..................................................................................................1261 Throttle/Accelerator Pedal............................................................................................1261 GRADE/SPEED CHART.........................................................................................................1262 OVERHEAD PANEL AND DISPLAYS...............................................................................................1263 CENTER CONSOLE............................................................................................................1264 Directional Control Lever.............................................................................................1264 Override/Fault Reset Switch...........................................................................................1265 Engine Shutdown Switch................................................................................................1265 Window Control Switches...............................................................................................1265 Hoist Control Lever...................................................................................................1265 Retarder Speed Control (RSC) Adjustment Dial..........................................................................1266 Retarder Speed Control (RSC) Switch...................................................................................1266 Data Store Button.....................................................................................................1267 KOMTRAX Plus Snapshot In Progress Light...............................................................................1267 Link Energized Light..................................................................................................1267 Service Engine Light..................................................................................................1267 12V Auxiliary Power Outlets...........................................................................................1267 Fire Suppression Control Outlet.......................................................................................1267 Communication Radio Outlet............................................................................................1267 DIAGNOSTIC PORTS..........................................................................................................1267 KOMTRAX Plus Diagnostic Port..........................................................................................1267 Interface Module (IM) Diagnostic Port.................................................................................1267 Payload Meter Diagnostic Port.........................................................................................1267 Truck Control Interface (TCI) Diagnostic Port.........................................................................1267 Propulsion System Controller (PSC) Diagnostic Port....................................................................1267 Engine Diagnostic Port (CENSE)........................................................................................1267 Engine Diagnostic Port (QUANTUM)......................................................................................1267 INSTRUMENT PANEL..........................................................................................................1268 Control Symbols.......................................................................................................1268 Key Switch............................................................................................................1270 Rotating Beacon Light Switch (optional)...............................................................................1270 Heated Mirror Switch (optional).......................................................................................1270 AC Drive System Rest Switch...........................................................................................1270 Wheel Brake Lock Switch...............................................................................................1271 Hazard Warning Light Switch...........................................................................................1271 Heater/Air Conditioner Vents..........................................................................................1271 Engine Oil Pressure Gauge.............................................................................................1271 Right Turn Signal Indicator...........................................................................................1271 Digital Tachometer....................................................................................................1271 High Beam Indicator...................................................................................................1271 Speedometer/Payload Meter Display.....................................................................................1271 Left Turn Signal Indicator............................................................................................1272 Coolant Temperature Gauge.............................................................................................1272 Lamp Check Switch.....................................................................................................1272 Light Switch (3-Way)..................................................................................................1272 Ladder Light Switch...................................................................................................1272 Backup Light Switch...................................................................................................1272 Fog Light Switch......................................................................................................1273 Payload Meter Switch..................................................................................................1273 Panel Illumination Light Dimmer Switch................................................................................1273 Hydraulic Oil Temperature Gauge.......................................................................................1273 Engine Hourmeter......................................................................................................1273 Fuel Gauge............................................................................................................1273 OVERHEAD STATUS / WARNING INDICATORS......................................................................................1274 A1. High Brake Oil Temperature........................................................................................1275 B1. Low Steering Pressure.............................................................................................1275 C1. Low Accumulator Precharge Pressure................................................................................1276 D1. Not used..........................................................................................................1276 E1. Low Brake Pressure................................................................................................1276 A2. Low Hydraulic Tank Level..........................................................................................1276 B2. Low Automatic Lubrication System Pressure.........................................................................1276 C2. Circuit Breaker Tripped...........................................................................................1276 D2. Hydraulic Oil Filter Monitor......................................................................................1277 E2. Low Fuel..........................................................................................................1277 A3. Parking Brake.....................................................................................................1277 B3. Service Brake.....................................................................................................1277 C3. Body Up...........................................................................................................1277 D3. Dynamic Retarding.................................................................................................1277 E3. Stop Engine.......................................................................................................1278 A4. Cranking Motor Failure............................................................................................1278 B4. Backup Lights.....................................................................................................1278 C4. Engine Shutdown Timer.............................................................................................1278 D4. Retard Speed Control (RSC) Indicator..............................................................................1278 E4. Check Engine......................................................................................................1278 A5. No Power..........................................................................................................1279 B5. Propulsion System Warning.........................................................................................1279 C5. Propulsion System Temperature.....................................................................................1279 D5. System/Component Failure..........................................................................................1279 E5. Battery Charging System Failure...................................................................................1279 A6. No Propel.........................................................................................................1279 B6. Propel System At Rest.............................................................................................1279 C6. Propel System Not Ready...........................................................................................1280 D6. Reduced Propulsion................................................................................................1280 E6. Retard At Continuous Level........................................................................................1280 D7. Brake Test Light..................................................................................................1280 E7. Maintenance Monitor...............................................................................................1280 8. Brake Test Switch..................................................................................................1280 REAR AXLE LIGHT BAR.......................................................................................................1281 Backup Lights.........................................................................................................1281 Retard Lights.........................................................................................................1281 Brake Lights..........................................................................................................1281 Backup Alarm..........................................................................................................1281 KOMTRAX PLUS..............................................................................................................1282 Operation.............................................................................................................1282 Interface Module......................................................................................................1284 Basic Precautions.....................................................................................................1284 KOMATSU WIRELESS BRIDGE (Optional)........................................................................................1285 General Information...................................................................................................1285 Communication Setup...................................................................................................1285 Switching to the KWB_SETUP Network....................................................................................1285 Setting the Computer Subnet Mask and IP Address.......................................................................1286 Properties............................................................................................................1286 Setting Up the KWB....................................................................................................1287 Adding Encryption.....................................................................................................1287 Final Computer Settings...............................................................................................1287 Data Downloading......................................................................................................1288 Resetting the KWB.....................................................................................................1288 KWB Lights............................................................................................................1288 SECTION P LUBRICATION AND SERVICE.....................................................................................................1289 SECTION P2 LUBRICATION AND SERVICE................................................................................................1291 LUBRICATION AND SERVICE.......................................................................................................1293 GENERAL...................................................................................................................1293 SERVICE CAPACITIES........................................................................................................1293 HYDRAULIC TANK SERVICE....................................................................................................1293 Adding Oil............................................................................................................1293 COOLING SYSTEM SERVICE....................................................................................................1294 Radiator Filling Procedure............................................................................................1294 Coolant Specifications................................................................................................1294 Unacceptable Practices................................................................................................1294 WHEEL MOTOR SERVICE.......................................................................................................1294 RESERVE OIL TANK SERVICE..................................................................................................1295 Filling the Reserve Oil Tank (Remote Fill)............................................................................1295 Inline Screen.........................................................................................................1295 QUICK FILL SERVICE CENTER.................................................................................................1296 LUBRICATION CHART.........................................................................................................1297 10 HOUR (DAILY) INSPECTIONS...............................................................................................1298 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................1301 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1301 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1301 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1304 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................1306 5000 HOUR MAINTENANCE CHECKS..............................................................................................1306 SECTION P3 AUTOMATIC LUBRICATION SYSTEM...........................................................................................1307 AUTOMATIC LUBRICATION SYSTEM..................................................................................................1309 GENERAL DESCRIPTION.......................................................................................................1309 SYSTEM COMPONENTS.........................................................................................................1311 Filter................................................................................................................1311 Hydraulic Motor and Pump..............................................................................................1311 Grease Reservoir......................................................................................................1311 Pressure Reducing Valve...............................................................................................1311 Flow Control Valve....................................................................................................1311 Solenoid Valve........................................................................................................1311 Vent Valve............................................................................................................1311 Lubrication Cycle Timer...............................................................................................1311 Over Pressure Cut Off Switch..........................................................................................1311 Grease Pressure Failure Switch........................................................................................1311 Injectors.............................................................................................................1311 Relief Valve (unloader valve).........................................................................................1311 SYSTEM OPERATION..........................................................................................................1312 Normal Operation......................................................................................................1312 Lubricant Required For System.........................................................................................1313 System Priming........................................................................................................1313 Filter Assembly.......................................................................................................1313 LUBRICANT PUMP............................................................................................................1314 Pump Housing Oil Level................................................................................................1314 Pump Pressure Control.................................................................................................1314 INJECTORS (SL-1 Series “H”)...............................................................................................1315 Injector Specifications...............................................................................................1315 Injector Adjustment...................................................................................................1315 INJECTOR OPERATION....................................................................................................1316 PREVENTIVE MAINTENANCE PROCEDURES.........................................................................................1317 Daily Lubrication System Inspection...................................................................................1317 250 Hour Inspection...................................................................................................1317 1000 Hour Inspection..................................................................................................1317 SYSTEM CHECKOUT...........................................................................................................1318 Lubrication Controller Check..........................................................................................1318 Lubrication Controller Components.....................................................................................1318 Lubrication Controller Adjustment.....................................................................................1318 SYSTEM TROUBLESHOOTING CHART..................................................................................................1320 SECTION Q ALPHABETICAL INDEX..........................................................................................................1323 SECTION R SYSTEM SCHEMATICS INDEX.....................................................................................................1327 HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC.......................................................................1329 HYDRAULIC BRAKE SYSTEM SCHEMATIC..................................................................................................1330 ELECTRICAL SCHEMATICS.............................................................................................................1331
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