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KOMATSU 930E-4SE DUMP TRUCK SERVICE REPAIR MANUAL (SN:A31165 & UP) – PDF DOWNLOAD
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- KOMATSU 930E-4SE DUMP TRUCK SERVICE REPAIR MANUAL
- Serial Number:A31165 & UP
- Publication Number:CEBM027101
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Description
KOMATSU 930E-4SE DUMP TRUCK SERVICE REPAIR MANUAL (SN:A31165 & UP)
KOMATSU 930E-4SE DUMP TRUCK SERVICE REPAIR MANUAL (SN:A31165 & UP) – PDF DOWNLOAD:
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KOMATSU 930E-4SE DUMP TRUCK SERVICE REPAIR MANUAL (SN:A31165 & UP)
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise.
- When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts in the General Information section of this manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.
- A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.
- The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, see the end of Section A4. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
TABLE OF CONTENTS:
KOMATSU 930E-4SE DUMP TRUCK SERVICE REPAIR MANUAL (SN:A31165 & UP)
COVER................................................................................................................................. 1 FOREWORD.............................................................................................................................. 5 TABLE OF CONTENTS..................................................................................................................... 7 SECTION A GENERAL INFORMATION......................................................................................................... 9 COMPONENTS & SPECIFICATIONS....................................................................................................... 11 MAJOR COMPONENT DESCRIPTIONS.................................................................................................. 11 Truck And Engine.......................................................................................................... 11 Main Alternator........................................................................................................... 11 AC Induction Traction Motorized Wheels.................................................................................... 11 Suspension................................................................................................................ 11 Operator's Cab............................................................................................................ 11 Power Steering............................................................................................................ 11 Dynamic Retarding......................................................................................................... 11 Brake System.............................................................................................................. 11 SPECIFICATIONS................................................................................................................ 13 ENGINE.................................................................................................................... 13 AC ELECTRIC DRIVE SYSTEM.................................................................................................. 13 DYNAMIC RETARDING......................................................................................................... 13 BATTERY ELECTRIC SYSTEM................................................................................................... 13 SERVICE CAPACITIES........................................................................................................ 13 HYDRAULIC SYSTEMS......................................................................................................... 14 SERVICE BRAKES............................................................................................................ 14 STEERING.................................................................................................................. 14 TIRES..................................................................................................................... 14 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS.............................................................................. 14 WEIGHT DISTRIBUTION....................................................................................................... 15 SAFETY............................................................................................................................ 17 GENERAL....................................................................................................................... 17 Safety Rules.............................................................................................................. 17 Safety Features........................................................................................................... 17 Fire Extinguisher And First Aid Kit....................................................................................... 17 Clothing And Personal Items............................................................................................... 17 Leaving The Operator’s Seat............................................................................................... 18 Mounting And Dismounting.................................................................................................. 18 Fire Prevention For Fuel And Oil.......................................................................................... 18 Precautions With High Temperature Fluids.................................................................................. 19 Asbestos Dust Hazard Prevention........................................................................................... 19 Prevention Of Injury By Work Equipment.................................................................................... 19 Unauthorized Modification................................................................................................. 19 Precautions When Using ROPS............................................................................................... 19 Precautions For Attachments............................................................................................... 20 Precautions For Starting The Truck........................................................................................ 20 PRECAUTIONS BEFORE OPERATION.................................................................................................. 20 Safety At The Worksite.................................................................................................... 20 Fire Prevention........................................................................................................... 21 Ventilation In Enclosed Areas............................................................................................. 21 Preparing For Operation................................................................................................... 21 Mirrors, Windows And Lights............................................................................................... 21 In The Operator Cab (Before Starting The Engine).......................................................................... 21 Seat Belts................................................................................................................ 21 OPERATING THE TRUCK........................................................................................................... 22 When Starting The Engine.................................................................................................. 22 General Truck Operation................................................................................................... 22 Ensuring Good Visibility.................................................................................................. 22 Traveling................................................................................................................. 23 Traveling In Reverse...................................................................................................... 23 Traveling On Slopes....................................................................................................... 23 Operating On Snow Or Ice.................................................................................................. 23 Avoid Damage To Dump Body................................................................................................. 23 Driving Near High Voltage Cables.......................................................................................... 24 Working On Loose Ground................................................................................................... 24 When Dumping.............................................................................................................. 24 When Loading.............................................................................................................. 24 Parking The Truck......................................................................................................... 24 Towing.................................................................................................................... 24 WORKING NEAR BATTERIES........................................................................................................ 25 Battery Hazard Prevention................................................................................................. 25 Jump Starting With Booster Cables......................................................................................... 26 Jump Starting With Receptacles............................................................................................ 26 BEFORE PERFORMING MAINTENANCE................................................................................................. 27 Stopping The Engine Before Service........................................................................................ 27 Warning Tag............................................................................................................... 27 Proper Tools.............................................................................................................. 27 Use of Tie-Off Anchor During Maintenance and Repair....................................................................... 27 Securing The Dump Body.................................................................................................... 28 WHILE PERFORMING MAINTENANCE.................................................................................................. 29 Keep The Truck Clean...................................................................................................... 29 Attachments............................................................................................................... 29 Working Under The Truck................................................................................................... 29 Rotating Fan And Belts.................................................................................................... 29 Waste Materials........................................................................................................... 29 Adding Fuel Or Oil........................................................................................................ 30 Radiator Coolant Level.................................................................................................... 30 Use Of Lighting........................................................................................................... 30 Precautions With The Battery.............................................................................................. 30 Handling High Pressure Hoses.............................................................................................. 30 Precautions With High Pressure Oil........................................................................................ 30 Performing Maintenance Near High Temperature Or High Pressure............................................................. 30 TIRES......................................................................................................................... 31 Handling Tires............................................................................................................ 31 Tire Maintenance.......................................................................................................... 31 Storing Tires After Removal............................................................................................... 31 WHEN REPAIRS ARE NECESSARY.................................................................................................... 32 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS............................................................................ 33 Preliminary Procedures Before Welding or Performing Maintenance........................................................... 33 Engine Shutdown Procedure Before Welding or Performing Maintenance........................................................ 33 CAPACITOR DISCHARGE SYSTEM.................................................................................................... 35 Necessary Tools........................................................................................................... 35 Warnings And Cautions..................................................................................................... 36 Manual DC Link Capacitor Discharge Procedure.............................................................................. 37 Failure of the Discharge System........................................................................................... 39 Manual Discharge of Capacitors............................................................................................ 40 Short Isolated Capacitor Terminals........................................................................................ 42 OPERATING INSTRUCTIONS............................................................................................................ 43 PREPARING FOR OPERATION....................................................................................................... 43 WALK AROUND INSPECTION........................................................................................................ 43 RETRACTABLE LADDER SYSTEM (Optional).......................................................................................... 47 Description............................................................................................................... 47 Normal Operation.......................................................................................................... 47 General Safety............................................................................................................ 47 IN-CAB CONTROL PANEL.......................................................................................................... 48 Digital Display Screen.................................................................................................... 48 Command Buttons........................................................................................................... 48 USING THE IN-CAB CONTROL PANEL................................................................................................ 49 Raising the Ladder........................................................................................................ 50 Lowering the Ladder....................................................................................................... 50 USING THE GROUND LEVEL CONTROL BOX............................................................................................ 51 Raising the Ladder........................................................................................................ 51 Lowering the Ladder....................................................................................................... 51 EMERGENCY OPERATION........................................................................................................... 51 ENGINE START-UP............................................................................................................... 52 AFTER ENGINE HAS STARTED...................................................................................................... 53 PRE-SHIFT BRAKE CHECK......................................................................................................... 53 Events.................................................................................................................... 53 OPERATION..................................................................................................................... 54 Description............................................................................................................... 54 Brake Test Exit Criteria.................................................................................................. 54 PERFORMING THE BRAKE TESTS.................................................................................................... 55 Setup..................................................................................................................... 55 Service Brake Test........................................................................................................ 55 Parking Brake Test........................................................................................................ 56 Retard System Test........................................................................................................ 57 EMERGENCY STEERING SYSTEM..................................................................................................... 57 Operation................................................................................................................. 57 Pre-Operation Testing..................................................................................................... 57 MACHINE OPERATION SAFETY PRECAUTIONS.......................................................................................... 58 OPERATING ON THE HAUL ROAD.................................................................................................... 59 STARTING ON A GRADE WITH A LOADED TRUCK....................................................................................... 60 PASSING....................................................................................................................... 60 LOADING....................................................................................................................... 60 Overload Speed Limit Function............................................................................................. 60 DUMPING....................................................................................................................... 61 Raising The Dump Body..................................................................................................... 61 Lowering The Dump Body (When dumping on flat ground)...................................................................... 62 Lowering The Dump Body (When dumping over a berm or into a crusher)....................................................... 62 TOWING........................................................................................................................ 63 Special Wiring Harness.................................................................................................... 63 SAFE PARKING PROCEDURES....................................................................................................... 65 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................................................................. 65 SUDDEN LOSS OF ENGINE POWER................................................................................................... 66 FUEL DEPLETION................................................................................................................ 66 DISABLED TRUCK DUMPING PROCEDURE.............................................................................................. 67 Hookup.................................................................................................................... 67 Raising the Body.......................................................................................................... 67 Lowering the Body......................................................................................................... 67 WARNINGS AND CAUTIONS............................................................................................................. 69 GRADE/SPEED CHART............................................................................................................. 69 KEY SWITCH.................................................................................................................... 69 ROPS/FOPS..................................................................................................................... 69 BATTERIES..................................................................................................................... 70 CAPACITORS.................................................................................................................... 70 CRUSHING HAZARD............................................................................................................... 71 CYLINDER PRESSURE............................................................................................................. 71 FILLING THE HYDRAULIC TANK.................................................................................................... 72 HYDRAULIC OIL PRESSURE........................................................................................................ 72 HOT OIL SPRAY................................................................................................................. 73 WHEEL MOTOR OIL LEVEL......................................................................................................... 73 HOT EXHAUST................................................................................................................... 73 RADIATOR...................................................................................................................... 73 EMERGENCY LADDER.............................................................................................................. 73 ACCUMULATOR DRAIN VALVES...................................................................................................... 73 EMERGENCY DUMP PROCEDURE...................................................................................................... 74 EMERGENCY TOWING PROCEDURE.................................................................................................... 74 WELDING....................................................................................................................... 74 EMERGENCY SHUTDOWN............................................................................................................ 74 INFORMATION DISPLAY........................................................................................................... 75 WIRELESS SIGNALS.............................................................................................................. 75 HIGH VOLTAGE.................................................................................................................. 75 LIFTING INSTRUCTIONS.......................................................................................................... 76 PRODUCT IDENTIFICATION PLATE.................................................................................................. 77 LUBRICATION CHART............................................................................................................. 78 TORQUE TABLES AND CONVERSION CHARTS............................................................................................... 79 STORAGE AND IDLE MACHINE PREPARATION.............................................................................................. 89 SHORT TERM IDLE PERIODS....................................................................................................... 89 PREPARATION FOR STORAGE....................................................................................................... 90 REMOVAL FROM STORAGE.......................................................................................................... 91 RECONDITIONING AN IDLE VEHICLE................................................................................................ 93 ENGINE OPERATION.............................................................................................................. 95 After The Engine Has Started.............................................................................................. 96 ENGINE STORAGE................................................................................................................ 97 Temporary Storage (30 Days Or Less)....................................................................................... 97 Extended Storage (More Than 30 Days)...................................................................................... 97 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................................................................... 99 ELECTRIC DRIVE TRUCKS......................................................................................................... 100 Storing A Truck That Is Operational....................................................................................... 100 Storing A Truck That Is Not Operational................................................................................... 101 Storing A Major Component................................................................................................. 102 Periodic Inspections...................................................................................................... 102 Placing Equipment Into Service After Storage.............................................................................. 102 SECTION B STRUCTURES.................................................................................................................. 105 SECTION B2 STRUCTURAL COMPONENTS.................................................................................................. 107 STRUCTURAL COMPONENTS......................................................................................................... 109 PREPARATION............................................................................................................... 109 DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY................................................................................. 110 Removal............................................................................................................... 110 Installation.......................................................................................................... 110 RH DECK AND RETARDING GRID................................................................................................ 111 Removal............................................................................................................... 111 Installation.......................................................................................................... 111 LH DECK................................................................................................................... 112 Removal............................................................................................................... 112 Installation.......................................................................................................... 112 CENTER DECK............................................................................................................... 113 Removal............................................................................................................... 113 Installation.......................................................................................................... 113 SECTION B3 DUMP BODY.............................................................................................................. 115 DUMP BODY..................................................................................................................... 117 DUMP BODY................................................................................................................. 117 Removal............................................................................................................... 117 Installation.......................................................................................................... 118 BODY PADS................................................................................................................. 119 Body Pad Shimming Procedure........................................................................................... 120 BODY GUIDE................................................................................................................ 121 HOIST LIMIT SWITCH........................................................................................................ 121 BODY-UP SWITCH............................................................................................................ 121 BODY RETENTION SLING...................................................................................................... 121 ROCK EJECTORS............................................................................................................. 122 Inspection............................................................................................................ 122 SECTION B4 FUEL TANK.............................................................................................................. 123 FUEL TANK..................................................................................................................... 125 FUEL TANK................................................................................................................. 125 Removal............................................................................................................... 125 Repair................................................................................................................ 125 Cleaning.............................................................................................................. 125 Installation.......................................................................................................... 125 FUEL TANK VENT ASSEMBLY................................................................................................... 127 Disassembly........................................................................................................... 127 Assembly.............................................................................................................. 127 FUEL GAUGE SENDER......................................................................................................... 128 Removal............................................................................................................... 128 Installation.......................................................................................................... 128 QUICK FILL FUEL RECEIVERS................................................................................................. 128 SECTION B4 FUEL TANK.............................................................................................................. 129 FUEL TANK..................................................................................................................... 131 FUEL TANK................................................................................................................. 131 Removal............................................................................................................... 131 Repair................................................................................................................ 131 Cleaning.............................................................................................................. 131 Installation.......................................................................................................... 131 FUEL TANK VENT ASSEMBLY................................................................................................... 133 Disassembly........................................................................................................... 133 Assembly.............................................................................................................. 133 FUEL GAUGE SENDER......................................................................................................... 134 Removal............................................................................................................... 134 Installation.......................................................................................................... 134 QUICK FILL FUEL RECEIVERS................................................................................................. 134 SECTION C ENGINE...................................................................................................................... 135 SECTION C2 POWER MODULE........................................................................................................... 137 POWER MODULE.................................................................................................................. 139 PREPARATION FOR REMOVAL................................................................................................... 139 REMOVAL................................................................................................................... 144 INSTALLATION.............................................................................................................. 146 HOOKUP.................................................................................................................... 147 SECTION C3 COOLING SYSTEM......................................................................................................... 149 COOLING SYSTEM................................................................................................................ 151 RADIATOR.................................................................................................................. 151 Removal............................................................................................................... 151 Installation.......................................................................................................... 153 Filling Procedure..................................................................................................... 154 REPAIRING THE RADIATOR.................................................................................................... 154 Internal Inspection................................................................................................... 154 External Cleaning..................................................................................................... 154 Disassembly........................................................................................................... 155 Cleaning and Inspection............................................................................................... 156 Assembly.............................................................................................................. 156 Pressure Testing...................................................................................................... 157 COOLANT SYSTEM TROUBLESHOOTING............................................................................................ 157 SECTION C4 POWER TRAIN............................................................................................................ 159 POWER TRAIN................................................................................................................... 161 ALTERNATOR REMOVAL........................................................................................................ 161 ALTERNATOR INSTALLATION................................................................................................... 163 Measuring Procedure................................................................................................... 163 Joining the Alternator and Engine..................................................................................... 165 ENGINE.................................................................................................................... 166 Removal............................................................................................................... 166 Service............................................................................................................... 166 Installation.......................................................................................................... 166 SECTION C5 AIR CLEANERS........................................................................................................... 167 AIR CLEANERS.................................................................................................................. 169 OPERATION................................................................................................................. 169 SERVICING THE AIR CLEANERS................................................................................................ 169 Replacing The Elements................................................................................................ 170 AIR CLEANER ASSEMBLY CLEANING............................................................................................. 171 Primary Element Cleaning.............................................................................................. 171 Precleaner Section Cleaning........................................................................................... 173 AIR INTAKE TROUBLESHOOTING................................................................................................ 174 SECTION C7 FAN CLUTCH............................................................................................................. 175 FAN CLUTCH.................................................................................................................... 177 REMOVAL & INSTALLATION TOOLING............................................................................................ 177 DISASSEMBLY............................................................................................................... 180 CLEANING AND INSPECTION................................................................................................... 190 ASSEMBLY.................................................................................................................. 194 TEST PROCEDURE............................................................................................................ 208 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION).................................................................................... 209 SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM......................................................................................... 211 24VDC ELECTRIC SUPPLY SYSTEM.................................................................................................. 213 ELECTRICAL SYSTEM DESCRIPTION............................................................................................. 213 BATTERIES................................................................................................................. 213 Maintenance and Service............................................................................................... 213 Troubleshooting....................................................................................................... 213 BATTERY SUPPLY SYSTEM..................................................................................................... 215 24VDC Battery Charging Alternator..................................................................................... 215 Batteries............................................................................................................. 215 Engine Start Relays................................................................................................... 215 24VDC Auxiliary Battery Receptacles................................................................................... 215 Battery Disconnect Switches........................................................................................... 215 24VDC to 12VDC Converter.............................................................................................. 216 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)....................................................................... 216 Operation............................................................................................................. 216 Pressure Switch....................................................................................................... 216 Check Valve........................................................................................................... 217 Timer Solenoid........................................................................................................ 217 MAINTENANCE............................................................................................................... 217 Prelube System Operation Checks....................................................................................... 217 Check Valve........................................................................................................... 217 Timer Solenoid........................................................................................................ 217 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT................................................................................ 218 24VDC ELECTRIC START SYSTEM................................................................................................... 220 CRANKING MOTORS........................................................................................................... 220 Operation............................................................................................................. 220 Removal............................................................................................................... 220 Installation.......................................................................................................... 220 CRANKING MOTOR TROUBLESHOOTING............................................................................................ 221 Preliminary Inspection................................................................................................ 221 No-Load Test.......................................................................................................... 221 Interpreting Results of Tests......................................................................................... 222 Disassembly........................................................................................................... 222 Cleaning and Inspection............................................................................................... 223 Armature Servicing.................................................................................................... 225 Field Coil Checks..................................................................................................... 225 Field Coil Removal.................................................................................................... 225 SOLENOID CHECKS........................................................................................................... 226 Test.................................................................................................................. 226 Assembly.............................................................................................................. 227 Bearing Replacement:.................................................................................................. 227 Motor Assembly:....................................................................................................... 227 Pinion Clearance...................................................................................................... 228 MAGNETIC SWITCH........................................................................................................... 228 Removal............................................................................................................... 228 Installation.......................................................................................................... 228 Coil Test............................................................................................................. 229 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS..................................................................................... 231 24 VDC ELECTRICAL SYSTEM COMPONENTS........................................................................................... 233 BRAKE WARNING BUZZER...................................................................................................... 233 AUXILIARY CONTROL CABINET COMPONENTS...................................................................................... 233 Power Distribution Terminals.......................................................................................... 233 Control Power Relay................................................................................................... 233 Auto Lube Timer....................................................................................................... 233 Ground Level Power Relay.............................................................................................. 233 Diode Board - DB1..................................................................................................... 235 Fuse Blocks........................................................................................................... 236 Alarm Indicating Device (AID) System.................................................................................. 236 RELAY BOARDS.............................................................................................................. 239 Relay Boards RB1, RB3, RB4, RB5....................................................................................... 239 Relay Board RB6, RB7, RB8, RB9........................................................................................ 241 Relay Board Functions................................................................................................. 242 BODY-UP SWITCH............................................................................................................ 244 Operation............................................................................................................. 244 Adjustment............................................................................................................ 244 Service............................................................................................................... 244 HOIST LIMIT SWITCH........................................................................................................ 245 Operation............................................................................................................. 245 Adjustment............................................................................................................ 245 Service............................................................................................................... 245 FUSE BLOCKS AND CIRCUIT BREAKERS.......................................................................................... 246 SECTION D11 KOMTRAX PLUS.......................................................................................................... 249 KOMTRAX PLUS.................................................................................................................. 251 KOMTRAX PLUS BASIC FEATURES............................................................................................... 251 Gather Data........................................................................................................... 251 Convert and Record Data............................................................................................... 251 Communicate Data to Off-Board Systems................................................................................. 252 USING KOMTRAX PLUS........................................................................................................ 253 Turning KOMTRAX Plus ON............................................................................................... 253 Normal KOMTRAX Plus Operation......................................................................................... 253 Turning KOMTRAX Plus OFF.............................................................................................. 254 Downloading from the KOMTRAX Plus Controller.......................................................................... 254 KOMTRAX PLUS DATA ITEMS................................................................................................... 255 Fault Codes........................................................................................................... 255 Machine History....................................................................................................... 255 KOMTRAX Plus History.................................................................................................. 255 Snapshots............................................................................................................. 256 Manual Snapshots...................................................................................................... 256 Trends................................................................................................................ 258 Histogram (Load Map) Data............................................................................................. 258 Haul Cycle Data....................................................................................................... 259 Alarm and Snapshot Triggers........................................................................................... 260 Satellite Features.................................................................................................... 260 KOMTRAX PLUS DIAGNOSTIC FEATURES.......................................................................................... 262 Fault History......................................................................................................... 262 LED Digits............................................................................................................ 262 KOMTRAX PLUS CONTROLLER................................................................................................... 262 Removal............................................................................................................... 263 Installation.......................................................................................................... 263 KOMTRAX PLUS SOFTWARE..................................................................................................... 264 VHMS Tool Box Installation............................................................................................ 264 VHMS Setting Tool Installation........................................................................................ 264 PDM Software Installation............................................................................................. 264 KOMTRAX PLUS INITIALIZATION PROCEDURE..................................................................................... 265 CONTROLLER SETUP PROCEDURE............................................................................................ 265 SNAPSHOT PROCEDURE.................................................................................................... 268 DOWNLOAD PROCEDURE.................................................................................................... 269 FTP UPLOAD PROCEDURE.................................................................................................. 270 INITIALIZATION FORMS.................................................................................................. 271 WHEN REPLACING A KOMTRAX PLUS CONTROLLER.................................................................................. 272 KOMTRAX PLUS CONTROLLER CHECKOUT.......................................................................................... 277 Necessary Equipment................................................................................................... 277 Preliminary........................................................................................................... 277 KOMTRAX Plus Controller Checkout Procedure............................................................................ 278 ORBCOMM CONTROLLER (if equipped).......................................................................................... 280 Removal............................................................................................................... 280 Installation.......................................................................................................... 280 SECTION D12 INTERFACE MODULE...................................................................................................... 281 INTERFACE MODULE.............................................................................................................. 283 Removal................................................................................................................... 283 Installation.............................................................................................................. 283 SENSORS....................................................................................................................... 284 Temperature Sensors....................................................................................................... 284 Pressure Sensors.......................................................................................................... 284 INTERFACE MODULE SOFTWARE..................................................................................................... 285 Flashburn Program Installation............................................................................................ 285 Interface Module Application Code Installation............................................................................ 286 Interface Module Realtime Data Monitor Software........................................................................... 286 INTERFACE MODULE CHECKOUT..................................................................................................... 287 Necessary Equipment....................................................................................................... 287 Preliminary............................................................................................................... 288 Check Digital Inputs To The Interface Module.............................................................................. 289 Check Analog Inputs To The Interface Module............................................................................... 292 Check Serial Interfaces To The Interface Module........................................................................... 292 Check Outputs From The Interface Module................................................................................... 293 SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX............................................................... 295 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING............................................................................. 297 GENERAL................................................................................................................... 297 TROUBLESHOOTING........................................................................................................... 298 Communications Networks............................................................................................... 298 Coaxial Cable......................................................................................................... 298 FAULT CODES............................................................................................................... 298 Fault History......................................................................................................... 298 KOMTRAX Plus LED Display Fault Codes.................................................................................. 299 Chassis Fault Codes................................................................................................... 300 Engine Fault Codes.................................................................................................... 304 FAULT TREE ANALYSIS....................................................................................................... 310 Unable to connect to KOMTRAX Plus from laptop PC...................................................................... 310 Flashing Error Code N4-23 (PLM III Communications Fault).............................................................. 311 Flashing Error Code N4-22 (Engine Communications Fault)............................................................... 312 No Data Received By WebCARE........................................................................................... 313 Coaxial Cable Troubleshooting......................................................................................... 314 SECTION D14 KOMTRAX PLUS FORMS.................................................................................................... 315 KOMTRAX PLUS FORMS............................................................................................................ 317 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 317 KOMTRAX PLUS DATA DOWNLOAD................................................................................................ 318 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 319 KOMTRAX PLUS INITIALIZATION FORM.......................................................................................... 321 SECTION E ELECTRIC PROPULSION SYSTEM.................................................................................................. 323 SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS.................................................................................. 325 ELECTRICAL PROPULSION SYSTEM COMPONENTS....................................................................................... 327 GENERAL SYSTEM DESCRIPTION................................................................................................ 327 SYSTEM COMPONENTS......................................................................................................... 329 Propulsion System Controller (PSC).................................................................................... 329 Truck Control Interface (TCI)......................................................................................... 330 Diagnostic Information Display (DID) Panel............................................................................ 331 DID Panel Event Codes................................................................................................. 331 PSC SOFTWARE FUNCTIONS.................................................................................................... 350 Input Processing...................................................................................................... 350 State Machine......................................................................................................... 350 DC Link State......................................................................................................... 353 Engine Control........................................................................................................ 354 ALTERNATOR FIELD CONTROL.................................................................................................. 354 Desired Three-Phase Voltage........................................................................................... 354 Desired DC Link Voltage............................................................................................... 354 Self-Load............................................................................................................. 355 Propel Torque Control................................................................................................. 355 Retard Torque Control................................................................................................. 355 Wheel Slide Control................................................................................................... 356 Resistor Grid Control................................................................................................. 356 Chopper Voltage Control............................................................................................... 356 EVENT DETECTION AND PROCESSING............................................................................................ 356 Power-On Tests........................................................................................................ 356 Initiated Tests....................................................................................................... 357 Periodic Tests........................................................................................................ 357 EVENT RESTRICTIONS........................................................................................................ 357 EVENT LOGGING AND STORAGE................................................................................................. 357 Event History Buffer.................................................................................................. 358 Data Packs............................................................................................................ 358 To Record and Save a Data Pack to a Disk.............................................................................. 358 Event Reset........................................................................................................... 359 SERIAL DATA COMMUNICATIONS................................................................................................ 359 PSC - TCI Communications Processing................................................................................... 359 PSC - PTU Communications Processing................................................................................... 359 Inverter Communications Processing.................................................................................... 360 OUTPUT PROCESSING......................................................................................................... 360 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS.................................................................................. 360 Fast Start............................................................................................................ 360 Engine Shutdown/Engine Not Running.................................................................................... 360 Limp Home Mode........................................................................................................ 361 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS..................................................................... 362 ELECTRONIC ACCELERATOR AND RETARD PEDALS.................................................................................. 370 Removal............................................................................................................... 370 Installation.......................................................................................................... 370 Disassembly........................................................................................................... 370 Assembly.............................................................................................................. 370 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.......................................................................... 371 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE................................................................................. 373 AC DRIVE SYSTEM MAINTENANCE............................................................................................... 373 NORMAL TRUCK SHUTDOWN PROCEDURE........................................................................................... 374 SHUTDOWN AFTER SYSTEM FAILURE............................................................................................. 374 SYSTEM CHECKOUT........................................................................................................... 375 Battery and Control Circuit Checks - Battery Power OFF................................................................ 375 Battery and Control Circuit Checks - Battery Power ON................................................................. 378 Checks with Key Switch OFF............................................................................................ 379 Checks with Key Switch ON............................................................................................. 379 CPU Battery Checks.................................................................................................... 379 MEMORY BACKUP BATTERY REPLACEMENT......................................................................................... 380 TCI PROGRAMMING........................................................................................................... 380 PSC PROGRAMMING........................................................................................................... 381 INVERTER PROGRAMMING...................................................................................................... 381 CPU RESET................................................................................................................. 381 PSC CHECKOUT.............................................................................................................. 382 PSC Digital Input Checks.............................................................................................. 382 PSC Digital Output Checks............................................................................................. 386 TCI CHECKOUT.............................................................................................................. 387 Modular Mining Communication Port Check............................................................................... 387 TCI Digital Input Checks.............................................................................................. 387 TCI Digital Output Tests.............................................................................................. 393 CALIBRATIONS.............................................................................................................. 395 Speedometer........................................................................................................... 395 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial.................................................................. 395 ERASING EVENTS............................................................................................................ 395 PSC................................................................................................................... 395 TCI................................................................................................................... 396 GATE DRIVER POWER CONVERTER TEST.......................................................................................... 396 LOAD TESTING.............................................................................................................. 397 Preparation........................................................................................................... 397 Alternator Speed Sensor Checks........................................................................................ 397 Battery Boost Check................................................................................................... 397 Brake Circuit Switch Checks........................................................................................... 398 Hoist & Steering Circuit Switch Checks................................................................................ 398 Link Energized Checks................................................................................................. 398 Loadbox Test.......................................................................................................... 400 TROUBLESHOOTING........................................................................................................... 404 PVM Optimum Load Curve Handshaking Troubleshooting.................................................................... 404 Phase Module and Chopper Module Troubleshooting....................................................................... 404 PHASE MODULE REPLACEMENT.................................................................................................. 405 Phase Module Removal.................................................................................................. 405 Phase Module Installation............................................................................................. 405 SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146)................................................................................ 407 Fault Code A001: Left front suspension pressure sensor signal is high......................................................... 409 Related circuit diagram................................................................................................... 409 Fault Code A002: Left front suspension pressure sensor signal is low.......................................................... 410 Related circuit diagram................................................................................................... 410 Fault Code A003: Right front suspension pressure sensor signal is high........................................................ 411 Related circuit diagram................................................................................................... 411 Fault Code A004: Right front suspension pressure sensor signal is low......................................................... 412 Related circuit diagram................................................................................................... 412 Fault Code A005: Left rear suspension pressure sensor signal is high.......................................................... 413 Related circuit diagram................................................................................................... 413 Fault Code A006: Left rear suspension pressure sensor signal is low........................................................... 414 Related circuit diagram................................................................................................... 414 Fault Code A007: Right rear suspension pressure sensor signal is high......................................................... 415 Related circuit diagram................................................................................................... 415 Fault Code A008: Right rear suspension pressure sensor signal is low.......................................................... 416 Related circuit diagram................................................................................................... 416 Fault Code A009: Incline sensor signal is high................................................................................ 417 Related circuit diagram................................................................................................... 417 Fault Code A010: Incline sensor signal is low................................................................................. 418 Related circuit diagram................................................................................................... 418 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 419 Related circuit diagram................................................................................................... 419 Fault Code A013: Body up switch has failed.................................................................................... 420 Related circuit diagram................................................................................................... 420 Fault Code A014: Payload meter checksum computation has failed................................................................ 421 Related circuit diagram................................................................................................... 421 Fault Code A016: Payload meter write to flash memory has failed............................................................... 422 Related circuit diagram................................................................................................... 422 Fault Code A017: Payload meter flash memory read has failed................................................................... 423 Related circuit diagram................................................................................................... 423 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 424 Related circuit diagram................................................................................................... 425 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 426 Related circuit diagram................................................................................................... 427 Fault Code A022: Carryback load is excessive.................................................................................. 428 Related circuit diagram................................................................................................... 429 Fault Code A026: Payload meter user select switch has failed.................................................................. 430 Related circuit diagram................................................................................................... 430 Fault Code A027: Payload meter user clear switch has failed................................................................... 431 Related circuit diagram................................................................................................... 431 Fault Code A101: High pressure detected across a hydraulic pump filter........................................................ 432 Related circuit diagram................................................................................................... 433 Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level................................... 434 Related circuit diagram................................................................................................... 435 Fault Code A107: GE has generated a propel system caution..................................................................... 436 Related circuit diagram................................................................................................... 437 Fault Code A108: GE has generated a propel system temperature caution......................................................... 438 Related circuit diagram................................................................................................... 439 Fault Code A109: GE has generated a propel system reduced level signal........................................................ 440 Related circuit diagram................................................................................................... 441 Fault Code A115: Low steering precharge pressure is detected.................................................................. 442 Related circuit diagram................................................................................................... 443 Fault Code A123: GE has generated a reduced retarding caution................................................................. 444 Related circuit diagram................................................................................................... 445 Fault Code A124: GE has generated a no propel / no retard warning............................................................. 446 Related circuit diagram................................................................................................... 447 Fault Code A125: GE has generated a no propel warning......................................................................... 448 Related circuit diagram................................................................................................... 449 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 450 Related circuit diagram................................................................................................... 451 Fault Code A127: IM furnished +5 volt output for sensors is low............................................................... 452 Related circuit diagram................................................................................................... 453 Fault Code A128: IM furnished +5 volt output for sensors is high.............................................................. 454 Related circuit diagram................................................................................................... 455 Fault Code A139, A310: Low fuel level warning................................................................................. 456 Related circuit diagram................................................................................................... 457 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 458 Related circuit diagram................................................................................................... 459 Fault Code A146: Hydraulic temperature sensors cause posting of this faultl................................................... 460 Related circuit diagram................................................................................................... 461 SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216)................................................................................ 463 Fault Code A152: Starter failure.............................................................................................. 464 Related circuit diagram................................................................................................... 465 Fault Code A153: Battery voltage is low with truck in operation............................................................... 466 Related circuit diagram................................................................................................... 467 Fault Code A154: Battery charging voltage is excessive........................................................................ 468 Related circuit diagram................................................................................................... 469 Fault Code A155: Battery charging voltage is low.............................................................................. 470 Related circuit diagram................................................................................................... 471 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 472 Related circuit diagram................................................................................................... 473 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 474 Related circuit diagram................................................................................................... 475 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 476 Related circuit diagram................................................................................................... 477 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 478 Related circuit diagram................................................................................................... 479 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 480 Related circuit diagram................................................................................................... 481 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 482 Related circuit diagram................................................................................................... 482 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 483 Related circuit diagram................................................................................................... 483 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 484 Related circuit diagram................................................................................................... 484 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 485 Related circuit diagram................................................................................................... 485 Fault Code A184: J1939 data link is not connected............................................................................. 486 Related circuit diagram................................................................................................... 487 Fault Code A190: Auto lube control has detected an incomplete lube cycle...................................................... 488 Related circuit diagram................................................................................................... 489 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 490 Related circuit diagram................................................................................................... 491 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 492 Related circuit diagram....................................................................................................... 493 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 494 Related circuit diagram....................................................................................................... 495 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 496 Related circuit diagram....................................................................................................... 497 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 498 Related circuit diagram................................................................................................... 498 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 499 Related circuit diagram................................................................................................... 499 Fault Code A200: Steering pressure sensor is high............................................................................. 500 Related circuit diagram................................................................................................... 500 Fault Code A201: Brake pressure sensor is high................................................................................ 501 Related circuit diagram................................................................................................... 501 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 502 Related circuit diagram................................................................................................... 502 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 503 Related circuit diagram................................................................................................... 503 Fault Code A204: Steering pressure sensor is low.............................................................................. 504 Related circuit diagram................................................................................................... 504 Fault Code A205: Brake pressure sensor is low................................................................................. 505 Related circuit diagram................................................................................................... 505 Fault Code A206: Ambient temperature sensor is high........................................................................... 506 Related circuit diagram................................................................................................... 506 Fault Code A207: Ambient temperature sensor is low............................................................................ 507 Related circuit diagram................................................................................................... 507 Fault Code A212: Bad truck speed signal....................................................................................... 508 Related circuit diagram................................................................................................... 509 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 510 Related circuit diagram................................................................................................... 512 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 514 Related circuit diagram................................................................................................... 516 Fault Code A215: Brake auto apply relay circuit is defective.................................................................. 518 Related circuit diagram................................................................................................... 519 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 520 Related circuit diagram................................................................................................... 521 SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292)................................................................................ 523 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 524 Related circuit diagram................................................................................................... 525 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 526 Related circuit diagram................................................................................................... 527 Fault Code A236: Steering accumulator has not properly bled down after 90 seconds............................................. 528 Related circuit diagram................................................................................................... 529 Fault Code A240: The keyswitch input to the interface module is open.......................................................... 530 Related circuit diagram................................................................................................... 531 Fault Code A246: Payload meter reports truck overload......................................................................... 531 Related circuit diagram................................................................................................... 531 Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted............................... 532 Related circuit diagram................................................................................................... 533 Fault Code A250: Battery voltage is low with the truck parked................................................................. 534 Related circuit diagram................................................................................................... 535 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 536 Related circuit diagram................................................................................................... 537 Fault Code A253: Steering bleed circuit is not open while running............................................................. 538 Related circuit diagram................................................................................................... 539 Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open.................................. 540 Related circuit diagram................................................................................................... 541 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 542 Related circuit diagram................................................................................................... 542 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 544 Related circuit diagram................................................................................................... 545 Fault Code A260: Parking brake failure........................................................................................ 546 Related circuit diagram................................................................................................... 547 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 548 Related circuit diagram................................................................................................... 549 Fault Code A263: Steering bleed circuit is shorted to ground.................................................................. 550 Related circuit diagram................................................................................................... 551 Fault Code A264: Parking brake relay circuit is defective..................................................................... 552 Related circuit diagram................................................................................................... 553 Fault Code A265: Service brake failure........................................................................................ 554 Related circuit diagram................................................................................................... 556 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 558 Related circuit diagram................................................................................................... 559 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 560 Related circuit diagram................................................................................................... 562 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 564 Related circuit diagram................................................................................................... 565 Fault Code A274: A brake setting fault has been detected...................................................................... 566 Related circuit diagram................................................................................................... 567 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 568 Related circuit diagram................................................................................................... 569 Fault Code A276: The drive system data link is not connected.................................................................. 570 Related circuit diagram................................................................................................... 571 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 572 Related circuit diagram................................................................................................... 573 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................... 574 Related circuit diagram................................................................................................... 575 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated...................... 576 Related circuit diagram................................................................................................... 577 Fault Code A285: The parking brake was not set when the key switch was turned off............................................. 578 Related circuit diagram................................................................................................... 579 Fault Code A286: A fault was detected in the shutdown delay relay circuit..................................................... 580 Related circuit diagram................................................................................................... 581 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off......................... 582 Related circuit diagram................................................................................................... 583 SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365)................................................................................ 585 Fault Code A303: Shifter is defective......................................................................................... 586 Related circuit diagram................................................................................................... 587 Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be............ 588 Related circuit diagram................................................................................................... 589 Fault Code A309: No brakes applied when expected.............................................................................. 590 Related circuit diagram................................................................................................... 592 Fault Code A311: Brake lock switch is on when it should not be................................................................ 594 Related circuit diagram................................................................................................... 595 Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings............................................ 596 Related circuit diagram................................................................................................... 596 Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings........................................... 597 Related circuit diagram................................................................................................... 597 Fault Code A315: DC-DC converter 12 volt circuit is low....................................................................... 598 Related circuit diagram................................................................................................... 599 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 600 Related circuit diagram................................................................................................... 601 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 602 Related circuit diagram................................................................................................... 604 Fault Code A318: Unexpected power loss to interface module.................................................................... 605 Related circuit diagram................................................................................................... 605 Fault Code A328: Drive system not powered up.................................................................................. 606 Related circuit diagram................................................................................................... 607 Fault Code A350: Overload on output 1B........................................................................................ 608 Related circuit diagram................................................................................................... 609 Fault Code A351: Overload on output 1E........................................................................................ 610 Related circuit diagram................................................................................................... 611 Fault Code A352: Overload on output 1H........................................................................................ 612 Related circuit diagram................................................................................................... 613 Fault Code A353: Overload on output 1J........................................................................................ 614 Related circuit diagram................................................................................................... 615 Fault Code A354: Overload on output 1K........................................................................................ 616 Related circuit diagram................................................................................................... 617 Fault Code A355: Overload on output 1L........................................................................................ 618 Related circuit diagram................................................................................................... 619 Fault Code A356: Overload on output 1M........................................................................................ 620 Related circuit diagram................................................................................................... 621 Fault Code A357: Overload on output 1N........................................................................................ 622 Related circuit diagram................................................................................................... 623 Fault Code A358: Overload on output 1P........................................................................................ 624 Related circuit diagram................................................................................................... 625 Fault Code A359: Overload on output 1R........................................................................................ 626 Related circuit diagram................................................................................................... 627 Fault Code A360: Overload on output 1S........................................................................................ 628 Related circuit diagram................................................................................................... 629 Fault Code A361: Overload on output 1T........................................................................................ 630 Related circuit diagram................................................................................................... 631 Fault Code A362: Overload on output 1U........................................................................................ 632 Related circuit diagram................................................................................................... 633 Fault Code A363: Overload on output 1X........................................................................................ 634 Related circuit diagram................................................................................................... 634 Fault Code A364: Overload on output 1Y........................................................................................ 636 Related circuit diagram................................................................................................... 637 Fault Code A365: Overload on output 1Z........................................................................................ 638 Related circuit diagram................................................................................................... 639 SECTION G REAR AXLE, SPINDLES AND WHEELS.............................................................................................. 641 SECTION G2 TIRES AND RIMS......................................................................................................... 643 TIRES AND RIMS................................................................................................................ 645 WHEEL STUD MAINTENANCE.................................................................................................... 646 FRONT TIRES AND RIMS...................................................................................................... 647 Removal............................................................................................................... 647 Installation.......................................................................................................... 648 REAR TIRES AND RIMS....................................................................................................... 649 Removal............................................................................................................... 649 Installation.......................................................................................................... 650 RIM....................................................................................................................... 651 Tire Removal.......................................................................................................... 651 Tire Installation..................................................................................................... 651 SECTION G3 FRONT WHEEL HUB AND SPINDLE............................................................................................ 653 FRONT WHEEL HUB AND SPINDLE................................................................................................... 655 WHEEL HUB AND SPINDLE ASSEMBLY............................................................................................ 655 Removal............................................................................................................... 655 Spindle Removal Procedure (off of the truck).......................................................................... 658 Installation.......................................................................................................... 660 Disassembly........................................................................................................... 661 Cleaning and Inspection............................................................................................... 663 Assembly.............................................................................................................. 663 Wheel Bearing Adjustment.............................................................................................. 664 Brake Installation.................................................................................................... 665 Seal Assembly Gap Check............................................................................................... 666 WHEEL SPEED SENSOR TESTING................................................................................................ 667 STEERING CYLINDERS........................................................................................................ 668 Spherical Bearing Wear Limits......................................................................................... 668 Removal............................................................................................................... 669 Installation.......................................................................................................... 669 Bearing Replacement (Steering Cylinder and Tie Rod)................................................................... 669 TIE ROD................................................................................................................... 671 Removal............................................................................................................... 671 Installation.......................................................................................................... 671 Disassembly........................................................................................................... 672 Assembly.............................................................................................................. 672 Toe-In Adjustment..................................................................................................... 673 TIE ROD INSPECTION AND TORQUE PROCEDURE................................................................................... 674 Old Style Tie Rod..................................................................................................... 674 New Style Tie Rod..................................................................................................... 675 SECTION G4 REAR AXLE MOUNTING..................................................................................................... 677 REAR AXLE MOUNTING............................................................................................................ 679 PIVOT PIN................................................................................................................. 679 Removal............................................................................................................... 679 Installation.......................................................................................................... 680 PIVOT EYE BEARING......................................................................................................... 680 Removal............................................................................................................... 680 Installation.......................................................................................................... 680 PIVOT EYE REPAIR.......................................................................................................... 681 Removal............................................................................................................... 681 Installation.......................................................................................................... 681 ANTI-SWAY BAR............................................................................................................. 682 Removal............................................................................................................... 682 Disassembly........................................................................................................... 682 Cleaning and Inspection............................................................................................... 682 Assembly.............................................................................................................. 682 Installation.......................................................................................................... 682 SECTION G5 REAR AXLE AND WHEEL MOTOR.............................................................................................. 685 REAR AXLE AND WHEEL MOTOR..................................................................................................... 687 REAR AXLE HOUSING......................................................................................................... 687 Preparation........................................................................................................... 687 Removal............................................................................................................... 688 Cleaning and Inspection............................................................................................... 689 Installation.......................................................................................................... 689 BLOWER PRESSURE SWITCH ADJUSTMENT......................................................................................... 689 WHEEL MOTOR............................................................................................................... 690 Preparation........................................................................................................... 690 Removal............................................................................................................... 691 Cleaning and Inspection............................................................................................... 693 Installation.......................................................................................................... 693 WHEEL MOTOR GEAR OIL...................................................................................................... 698 Filtering Requirements................................................................................................ 698 Particle Size Analysis................................................................................................ 698 Flushing.............................................................................................................. 698 Oil Sample Analysis................................................................................................... 699 ELEMENT SPECIFICATION CHARTS.............................................................................................. 700 SECTION H HYDRAIR® II SUSPENSIONS..................................................................................................... 703 SECTION H2 FRONT SUSPENSIONS...................................................................................................... 705 FRONT SUSPENSION.............................................................................................................. 707 Removal................................................................................................................... 707 Installation.............................................................................................................. 708 Inspection................................................................................................................ 713 LOWER BEARING & SEALS..................................................................................................... 714 Removal............................................................................................................... 714 Installation.......................................................................................................... 714 MAJOR SUSPENSION REBUILD.................................................................................................. 715 Disassembly........................................................................................................... 715 Assembly.............................................................................................................. 716 SUSPENSION PRESSURE TEST.................................................................................................. 717 SECTION H3 REAR SUSPENSIONS....................................................................................................... 719 REAR SUSPENSIONS.............................................................................................................. 721 SUSPENSION CYLINDER....................................................................................................... 722 Removal............................................................................................................... 722 Installation.......................................................................................................... 724 Disassembly........................................................................................................... 724 Cleaning and Inspection............................................................................................... 725 Assembly.............................................................................................................. 725 SUSPENSION PRESSURE TEST.................................................................................................. 727 SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES.............................................................................. 729 SUSPENSION OILING AND CHARGING PROCEDURE...................................................................................... 731 GENERAL................................................................................................................... 731 EQUIPMENT LIST............................................................................................................ 731 HYDRAIR® CHARGING KIT..................................................................................................... 732 Installation of Charging Kit.......................................................................................... 732 Removal of Charging Kit............................................................................................... 732 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS......................................................................... 733 FRONT SUSPENSION.......................................................................................................... 733 Front Suspension Oiling............................................................................................... 733 Front Suspension Nitrogen Charging.................................................................................... 735 REAR SUSPENSION........................................................................................................... 736 Rear Suspension Oiling................................................................................................ 737 Rear Suspension Nitrogen Charging..................................................................................... 739 OIL AND NITROGEN SPECIFICATIONS CHARTS........................................................................................ 740 SECTION J BRAKE CIRCUIT............................................................................................................... 741 SECTION J2 BRAKE CIRCUIT.......................................................................................................... 743 BRAKE CIRCUIT................................................................................................................. 745 SERVICE BRAKE CIRCUIT..................................................................................................... 745 PARKING BRAKE CIRCUIT..................................................................................................... 747 BRAKE LOCK CIRCUIT........................................................................................................ 747 SECONDARY BRAKING AND AUTOMATIC APPLY..................................................................................... 748 WARNING CIRCUIT........................................................................................................... 748 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE........................................................................................ 751 BRAKE CIRCUIT COMPONENT SERVICE............................................................................................... 753 BRAKE VALVE............................................................................................................... 753 Rebuild Criteria...................................................................................................... 753 Removal............................................................................................................... 754 Installation.......................................................................................................... 754 Disassembly........................................................................................................... 755 Cleaning and Inspection............................................................................................... 758 Assembly.............................................................................................................. 758 Regulator Sleeve O-Ring Installation.................................................................................. 759 BRAKE VALVE BENCH TEST AND ADJUSTMENT..................................................................................... 761 Test Setup Procedure.................................................................................................. 762 Brake Valve Output Pressure Adjustment................................................................................ 762 Final Test and Adjustment............................................................................................. 763 Installing Brake Pedal Actuator Assembly to Brake Valve............................................................... 763 Installing Retard Pedal To Brake Pedal................................................................................ 763 DUAL RELAY VALVE.......................................................................................................... 764 Removal............................................................................................................... 764 Installation.......................................................................................................... 764 Disassembly........................................................................................................... 764 Cleaning and Inspection............................................................................................... 765 Assembly.............................................................................................................. 766 DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT................................................................................ 767 Test Setup Procedure.................................................................................................. 768 Relay Valve Output Pressure Adjustment................................................................................ 768 BRAKE MANIFOLD............................................................................................................ 769 Removal............................................................................................................... 769 Installation.......................................................................................................... 769 Disassembly........................................................................................................... 769 Cleaning and Inspection............................................................................................... 770 Assembly.............................................................................................................. 770 BRAKE ACCUMULATORS........................................................................................................ 770 Brake Accumulator Bleeddown Procedure................................................................................. 770 Removal............................................................................................................... 771 Installation.......................................................................................................... 771 Disassembly........................................................................................................... 772 Cleaning and Inspection............................................................................................... 773 Assembly.............................................................................................................. 773 Accumulator Charging Procedure........................................................................................ 775 Precharge Maintenance................................................................................................. 777 Accumulator Storage Procedures........................................................................................ 778 Bladder Storage Procedures............................................................................................ 778 Installing A Bladder Accumulator From Storage......................................................................... 778 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................................................... 779 Removal............................................................................................................... 779 Installation.......................................................................................................... 779 Disassembly........................................................................................................... 779 Lever Adjustments..................................................................................................... 779 Potentiometer Check................................................................................................... 780 Assembly.............................................................................................................. 780 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE...................................................................................... 783 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................................................. 785 REQUIRED EQUIPMENT........................................................................................................ 786 INITIAL SYSTEM SETUP...................................................................................................... 787 BRAKE LOCK / SECONDARY BRAKE CHECK-OUT.................................................................................... 788 PARKING BRAKE CHECK-OUT................................................................................................... 789 SERVICE BRAKE CHECK-OUT................................................................................................... 790 LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT......................................................................... 791 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART........................................................................... 792 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET......................................................................... 794 SECTION J5 WET DISC BRAKE ASSEMBLY................................................................................................ 797 WET DISC BRAKE ASSEMBLY....................................................................................................... 799 OPERATION................................................................................................................. 799 BRAKE DISC WEAR INSPECTION................................................................................................ 800 BRAKE REBUILD............................................................................................................. 801 Disassembly........................................................................................................... 801 Cleaning and Inspection............................................................................................... 805 Assembly.............................................................................................................. 806 Floating Ring Seal Assembly & Installation............................................................................ 811 WET DISC BRAKE BLEEDING PROCEDURE......................................................................................... 815 SECTION J7 PARKING BRAKE.......................................................................................................... 817 PARKING BRAKE................................................................................................................. 819 OPERATION................................................................................................................. 819 MAINTENANCE............................................................................................................... 820 Inspection............................................................................................................ 820 Removal............................................................................................................... 820 Installation.......................................................................................................... 821 Disassembly........................................................................................................... 821 Cleaning and Inspection............................................................................................... 821 Assembly.............................................................................................................. 823 Cleaning and Inspecting New Discs..................................................................................... 824 PARKING BRAKE BLEEDING PROCEDURE.......................................................................................... 825 SECTION L HYDRAULIC SYSTEM............................................................................................................ 827 SECTION L2 HYDRAULIC SYSTEM....................................................................................................... 829 HYDRAULIC SYSTEM.............................................................................................................. 831 HYDRAULIC PUMP MODULE..................................................................................................... 831 HOIST CIRCUIT OPERATION................................................................................................... 832 STEERING CIRCUIT OPERATION................................................................................................ 834 DISC BRAKE COOLING SYSTEM................................................................................................. 836 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR...................................................................................... 839 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................................................. 841 HOIST PUMP................................................................................................................ 841 Removal............................................................................................................... 841 Installation.......................................................................................................... 843 Inspection............................................................................................................ 848 Assembly.............................................................................................................. 848 HYDRAULIC TANK............................................................................................................ 854 Removal............................................................................................................... 854 Installation.......................................................................................................... 855 HYDRAULIC TANK BREATHERS.................................................................................................. 855 HYDRAULIC TANK STRAINERS.................................................................................................. 856 Removal............................................................................................................... 856 Inspect and Clean..................................................................................................... 856 Installation.......................................................................................................... 856 SECTION L4 STEERING CIRCUIT....................................................................................................... 857 STEERING CIRCUIT.............................................................................................................. 859 STEERING CIRCUIT OPERATION................................................................................................ 859 COMPONENT DESCRIPTION..................................................................................................... 860 Steering Control Unit................................................................................................. 860 Bleeddown Manifold.................................................................................................... 861 Steering Accumulator Bleed Down Solenoid.............................................................................. 861 Relief Valves......................................................................................................... 863 Hoist Up Limit Solenoid............................................................................................... 863 Steering Accumulators................................................................................................. 863 Low Precharge Warning Switch.......................................................................................... 863 High Pressure Filter.................................................................................................. 863 Quick Disconnect Ports................................................................................................ 863 Flow Amplifier........................................................................................................ 865 FLOW AMPLIFIER SYSTEM OPERATION........................................................................................... 866 No Steer.............................................................................................................. 866 Steering Left......................................................................................................... 868 Steering Right........................................................................................................ 870 No Steer, External Shock Load......................................................................................... 872 STEERING PUMP............................................................................................................. 874 Normal Operation...................................................................................................... 874 PRINCIPLE OF OPERATION.................................................................................................... 876 Full Pump Volume...................................................................................................... 876 Half Pump Volume...................................................................................................... 876 Neutral Position...................................................................................................... 876 Steering Pump......................................................................................................... 877 SECTION L5 STEERING CONTROL UNIT.................................................................................................. 879 STEERING CONTROL UNIT......................................................................................................... 881 REMOVAL................................................................................................................... 881 SPLINE INSPECTION......................................................................................................... 881 INSTALLATION.............................................................................................................. 882 DISASSEMBLY............................................................................................................... 882 CLEANING AND INSPECTION................................................................................................... 883 ASSEMBLY.................................................................................................................. 885 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR...................................................................................... 889 STEERING CIRCUIT COMPONENT REPAIR............................................................................................. 891 BLEEDDOWN MANIFOLD VALVE.................................................................................................. 891 Removal............................................................................................................... 891 Installation.......................................................................................................... 892 FLOW AMPLIFIER............................................................................................................ 893 Removal............................................................................................................... 893 Installation.......................................................................................................... 893 Disassembly........................................................................................................... 893 Assembly.............................................................................................................. 895 STEERING CYLINDERS........................................................................................................ 896 Disassembly........................................................................................................... 897 Piston Seal & Bearing Installation.................................................................................... 897 Assembly.............................................................................................................. 897 Testing............................................................................................................... 897 STEERING AND BRAKE PUMP................................................................................................... 898 Removal............................................................................................................... 898 Installation.......................................................................................................... 899 Disassembly........................................................................................................... 900 Inspection............................................................................................................ 903 Assembly.............................................................................................................. 906 Driveshaft Group...................................................................................................... 907 Rotating Group........................................................................................................ 907 Valve Plate Group..................................................................................................... 908 STEERING ACCUMULATORS..................................................................................................... 910 Removal............................................................................................................... 910 Installation.......................................................................................................... 910 Disassembly........................................................................................................... 911 Cleaning and Inspection............................................................................................... 911 Assembly.............................................................................................................. 912 Leak Testing.......................................................................................................... 914 Charging Procedure.................................................................................................... 915 Precharge Maintenance................................................................................................. 917 Accumulator Storage Procedures........................................................................................ 918 Bladder Storage Procedures............................................................................................ 918 Installing A Bladder Accumulator From Storage......................................................................... 918 TROUBLESHOOTING............................................................................................................... 919 STEERING CIRCUIT.......................................................................................................... 919 STEERING PUMP............................................................................................................. 921 Basic Hydraulic System Checks......................................................................................... 922 System Leakage Check.................................................................................................. 923 Steering Pump Troubleshooting Guide................................................................................... 925 Pump Pressure Control Checks.......................................................................................... 928 Pump Fails to Unload.................................................................................................. 929 Pump Fails to Develop Pressure........................................................................................ 929 Pump Slow in Developing Pressure...................................................................................... 930 Pump Control Valve Inspection and Troubleshooting..................................................................... 931 Pump Case Drain Check................................................................................................. 931 Setting Pump Pressure Controls........................................................................................ 933 Adjustment............................................................................................................ 934 SECTION L7 HOIST CIRCUIT.......................................................................................................... 935 HOIST CIRCUIT................................................................................................................. 937 BASIC OPERATION........................................................................................................... 937 COMPONENT DESCRIPTION..................................................................................................... 938 Hydraulic Tank........................................................................................................ 938 Hydraulic Pump........................................................................................................ 938 High Pressure Filters................................................................................................. 938 Hoist Valve........................................................................................................... 938 Inlet Sections........................................................................................................ 938 Work Ports (Rear) Spool Section....................................................................................... 939 Tank Ports (Front) Spool Section...................................................................................... 939 Hoist Pilot Valve..................................................................................................... 939 Bleeddown Manifold.................................................................................................... 940 Hoist Up Limit Solenoid............................................................................................... 940 Pilot Operated Check Valve............................................................................................ 940 Overcenter Manifold................................................................................................... 940 HOIST CIRCUIT OPERATION....................................................................................................... 941 Float Position Of Pilot Valve With Truck Body On Frame.................................................................... 942 Power Up Operation........................................................................................................ 944 Hold Operation............................................................................................................ 946 Power Down Operation...................................................................................................... 948 Float Operation........................................................................................................... 950 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR......................................................................................... 953 HOIST CIRCUIT COMPONENT REPAIR................................................................................................ 955 HOIST VALVE............................................................................................................... 955 Removal............................................................................................................... 955 Installation.......................................................................................................... 956 O-Ring Replacement.................................................................................................... 956 INLET SECTION............................................................................................................. 957 Disassembly........................................................................................................... 957 Cleaning and Inspection............................................................................................... 958 Assembly.............................................................................................................. 958 REAR SPOOL SECTION (Work Ports)........................................................................................... 959 Disassembly........................................................................................................... 959 Cleaning and Inspection............................................................................................... 959 Assembly.............................................................................................................. 961 FRONT SPOOL SECTION (Tank Ports).......................................................................................... 962 Disassembly........................................................................................................... 962 Cleaning and Inspection............................................................................................... 962 Assembly.............................................................................................................. 962 HOIST PILOT VALVE......................................................................................................... 964 Removal............................................................................................................... 964 Installation.......................................................................................................... 964 Disassembly........................................................................................................... 965 Cleaning and Inspection............................................................................................... 966 Assembly.............................................................................................................. 966 HOIST CYLINDERS........................................................................................................... 967 Removal............................................................................................................... 967 Installation.......................................................................................................... 968 Disassembly........................................................................................................... 970 Cleaning and Inspection............................................................................................... 971 Assembly - Quill...................................................................................................... 972 Assembly - Cylinder................................................................................................... 974 Testing............................................................................................................... 974 OVERCENTER VALVE MANIFOLD................................................................................................. 975 SECTION L9 HYDRAULIC SYSTEM FILTERS............................................................................................... 977 HYDRAULIC SYSTEM FILTERS...................................................................................................... 979 HOIST CIRCUIT FILTER...................................................................................................... 979 Filter Element Replacement............................................................................................ 979 Removal - Hoist Circuit Filter........................................................................................ 980 Installation - Hoist Circuit Filter................................................................................... 980 Indicator Switch - Hoist Circuit Filter............................................................................... 980 STEERING CIRCUIT FILTER................................................................................................... 981 Filter Element Replacement............................................................................................ 981 Removal - Steering Circuit Filter..................................................................................... 982 Installation - Steering Circuit Filter................................................................................ 982 Indicator Switch - Steering Circuit Filter............................................................................ 982 INDICATOR SWITCH.......................................................................................................... 982 Test Procedure........................................................................................................ 982 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE.......................................................................................... 985 HYDRAULIC CHECKOUT PROCEDURE.................................................................................................. 987 GENERAL INFORMATION....................................................................................................... 987 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................................................... 994 Equipment Requirements................................................................................................ 995 Pump Pressure Control Adjustments..................................................................................... 995 Steering Control Valve and Flow Amplifier Leakage Test................................................................ 996 Bleeddown Manifold Leakage Test....................................................................................... 997 STEERING/BRAKE PUMP STROKE ADJUSTMENT..................................................................................... 998 SHOCK AND SUCTION VALVES.................................................................................................. 998 Equipment Requirements................................................................................................ 998 Pressure Tests........................................................................................................ 998 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.............................................................1000 Equipment Requirements................................................................................................1000 Pressure Gauge Locations..............................................................................................1000 Brake Cooling Circuit Test............................................................................................1000 Power Up Relief Pressure Test.........................................................................................1001 Power Down Relief Pressure Test.......................................................................................1002 Counterbalance Valve Pressure Check...................................................................................1003 Counterbalance Valve Adjustment.......................................................................................1004 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET.........................................................................1005 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET............................................................1006 SECTION M OPTIONS AND SPECIAL TOOLS...................................................................................................1007 SECTION M7 HOT START SYSTEM.......................................................................................................1009 HOT START SYSTEM..............................................................................................................1011 SYSTEM OPERATION..........................................................................................................1011 HEATER INFORMATION........................................................................................................1012 TROUBLESHOOTING GUIDELINES................................................................................................1013 SECTION M8 SPECIAL TOOLS..........................................................................................................1015 HIGH VOLTAGE TOOLS............................................................................................................1019 0-2000 VDC CUSTOM METER KIT (58B-06-00800)....................................................................................1019 SECTION M19 RADIATOR SHUTTERS.....................................................................................................1023 RADIATOR SHUTTERS.............................................................................................................1025 OPERATION.................................................................................................................1025 Hydraulic Circuit.....................................................................................................1025 Electrical Circuit....................................................................................................1026 MAINTENANCE AND REPAIR....................................................................................................1026 TROUBLESHOOTING...........................................................................................................1027 SECTION M20 PAYLOAD METER III ™...................................................................................................1031 OPERATION SECTION.............................................................................................................1035 Introduction..............................................................................................................1035 Data Summary..........................................................................................................1035 Data Gathering........................................................................................................1035 COMPONENT DESCRIPTION.....................................................................................................1036 System Diagram........................................................................................................1036 Suspension Pressure Sensors...........................................................................................1036 Inclinometer..........................................................................................................1036 Operator Display......................................................................................................1036 Operator Switch.......................................................................................................1037 Speed Input...........................................................................................................1037 Body-Up Switch........................................................................................................1037 Brake Lock Switch.....................................................................................................1037 Payload Meter.........................................................................................................1037 Communications Ports..................................................................................................1037 Key Switch Input......................................................................................................1038 Payload Meter Power...................................................................................................1038 Load Lights...........................................................................................................1038 Wiring and Termination................................................................................................1039 TCI Outputs...........................................................................................................1039 OPERATOR’S DISPLAY AND SWITCH.............................................................................................1040 Reading the Speedometer...............................................................................................1040 Reading the Load Display..............................................................................................1040 Using the Operator ID.................................................................................................1040 Using the Load and Ton Counter........................................................................................1040 Total Ton Counter.....................................................................................................1040 Total Load Counter....................................................................................................1041 Clearing the Counters.................................................................................................1041 Viewing Live Sensor Data..............................................................................................1041 Other Display Messages................................................................................................1041 PAYLOAD OPERATION & CALCULATION...........................................................................................1042 Description of Haul Cycle States......................................................................................1042 Haul Cycle Description................................................................................................1042 Load Calculation......................................................................................................1043 Carry Back............................................................................................................1043 Measurement Accuracy..................................................................................................1043 SOURCES FOR PAYLOAD ERROR.................................................................................................1043 Payload Error.........................................................................................................1043 Loading Conditions....................................................................................................1044 Pressure Sensors......................................................................................................1044 Swingloads............................................................................................................1044 Speed and Distance....................................................................................................1044 HAUL CYCLE DATA...........................................................................................................1044 Haul Cycle Warning Flags..............................................................................................1046 Frame Torque Data.....................................................................................................1047 Sprung Weight Data....................................................................................................1047 Maximum Speed Data....................................................................................................1047 Alarm Records.........................................................................................................1047 Fault Code Data.......................................................................................................1048 PC SOFTWARE OVERVIEW......................................................................................................1049 System Configuration..................................................................................................1049 Installing the PLMIII Software........................................................................................1049 DOWNLOADING DATA..........................................................................................................1050 PLM III SYSTEM CONFIGURATION..............................................................................................1051 Starting Communications...............................................................................................1051 Displayed Payload Units...............................................................................................1051 Time Units............................................................................................................1051 Connection Menu.......................................................................................................1051 Connecting to the Payload Meter.......................................................................................1052 Configure the Payload Meter...........................................................................................1052 Setting the Date and Time.............................................................................................1052 Setting the Truck Type................................................................................................1053 Setting the Gauge Display Units.......................................................................................1053 Setting the Frame Serial Number.......................................................................................1053 Setting the Truck Number..............................................................................................1053 Setting the Komatsu Distributor.......................................................................................1053 Setting the Komatsu Customer..........................................................................................1053 Clean Truck Tare Calibration..........................................................................................1054 Inclinometer Calibration..............................................................................................1054 DATA ANALYSIS.............................................................................................................1055 Creating a Query......................................................................................................1055 Sorting on Truck Unit Number..........................................................................................1055 Sorting on Truck Type.................................................................................................1055 Sorting on Date Range.................................................................................................1056 Sorting on Time Range.................................................................................................1056 Payload Detail Screen.................................................................................................1057 Creating Reports......................................................................................................1057 Summary - one page report.............................................................................................1058 Detailed - multi-page report..........................................................................................1058 Creating Graphs.......................................................................................................1059 Exporting Data........................................................................................................1059 CSV Export............................................................................................................1059 Compressed............................................................................................................1060 Importing Data........................................................................................................1061 Deleting Haul Cycle Records...........................................................................................1061 Viewing Alarms........................................................................................................1062 Deleting Alarm Records................................................................................................1062 TROUBLESHOOTING SECTION.......................................................................................................1063 TROUBLESHOOTING...........................................................................................................1063 Viewing Active Alarms.................................................................................................1063 Real-Time Data Display................................................................................................1063 Testing the Payload Lights............................................................................................1063 Creating Log Files of Inputs..........................................................................................1064 Daily Inspections.....................................................................................................1064 Periodic Maintenance..................................................................................................1064 Abnormal Displays at Power-Up.........................................................................................1065 No Payload Display When Key Switch is Turned ON.......................................................................1066 No Display on Speedometer.............................................................................................1067 No Display on Operator Display........................................................................................1067 No Communications With PC.............................................................................................1068 Load Lights Don’t Light During Loading................................................................................1069 Load Lights Remain ON.................................................................................................1070 Load Lights Remain ON During Dumping..................................................................................1070 Display Doesn't Clear When The Load Is Dumped.........................................................................1070 Calibration Problems..................................................................................................1071 Alarm 1 - Left Front Pressure High....................................................................................1072 Alarm 2 - Left Front Pressure Low.....................................................................................1072 Troubleshoot Wiring to Left Front Suspension..........................................................................1072 Alarm 3 - Right Front Pressure High...................................................................................1073 Alarm 4 - Right Front Pressure Low....................................................................................1073 Troubleshoot Wiring to Right Front Suspension.........................................................................1073 Alarm 5 -Left Rear Pressure High......................................................................................1074 Alarm 6 - Left Rear Pressure Low......................................................................................1074 Troubleshoot Wiring to Left Rear Suspension...........................................................................1074 Alarm 7 - Right Rear Pressure High....................................................................................1075 Alarm 8 - Right Rear Pressure Low.....................................................................................1075 Troubleshoot Wiring to Right Rear Suspension..........................................................................1075 Alarm 9 - Inclinometer High...........................................................................................1076 Alarm 10 - Inclinometer Low...........................................................................................1076 Troubleshoot Inclinometer Wiring......................................................................................1076 Alarm 13 - Body Up Input Failure......................................................................................1077 Alarm 16 - Memory Write Failure.......................................................................................1078 Alarm 17 - Memory Read Failure........................................................................................1078 Alarm 18..............................................................................................................1079 Alarm 19..............................................................................................................1079 Alarm 22..............................................................................................................1079 Operator Switch Doesn't Work..........................................................................................1080 Alarm 26 - User Switch Fault - SELECT.................................................................................1080 Alarm 27 - User Switch Fault - SET....................................................................................1080 Connector Map.........................................................................................................1081 Connectors............................................................................................................1082 PLMIII CHECK OUT PROCEDURE....................................................................................................1083 General Description.......................................................................................................1083 Tools Required............................................................................................................1083 Checkout Procedure........................................................................................................1083 PLMIII CHECKOUT PROCEDURE CONFIRMATION....................................................................................1087 Flashburn Programming.................................................................................................1087 Confirmation Checklist................................................................................................1089 SECTION M31 RESERVE ENGINE OIL SYSTEM.............................................................................................1091 RESERVE ENGINE OIL SYSTEM.....................................................................................................1093 Operation.................................................................................................................1094 LED Monitor Light.........................................................................................................1094 Tank Fill Control (Optional)..............................................................................................1095 Filling Procedure (Remote Fill Feature)...................................................................................1095 SERVICE...................................................................................................................1096 Every 10 Hours, or once each shift:...................................................................................1096 Every 500 Hours.......................................................................................................1096 Changing Oil..........................................................................................................1096 TROUBLESHOOTING...........................................................................................................1097 Circuit Fuse..........................................................................................................1097 SYSTEM ELECTRICAL SCHEMATICS..............................................................................................1098 SECTION M32 RETRACTABLE LADDER SYSTEM.............................................................................................1099 RETRACTABLE LADDER SYSTEM.....................................................................................................1104 GENERAL SAFETY............................................................................................................1104 LADDER SYSTEM DESCRIPTION.................................................................................................1104 LADDER SYSTEM OPERATION...................................................................................................1104 Normal Operation......................................................................................................1104 Emergency Operation...................................................................................................1106 Limit Switch Operation................................................................................................1106 IN-CAB CONTROL PANEL......................................................................................................1106 IN-CAB CONTROL PANEL FEATURES.............................................................................................1108 Digital Display Screen................................................................................................1108 Command Buttons.......................................................................................................1108 IN-CAB CONTROL PANEL FUNCTIONS............................................................................................1110 Timing Control........................................................................................................1110 Ladder System Status..................................................................................................1110 Fault Code Identification.............................................................................................1110 Ladder System Configuration...........................................................................................1111 In-Cab Control Panel Lockout..........................................................................................1111 Automatic Raising.....................................................................................................1111 Diagnostics...........................................................................................................1111 Maintenance...........................................................................................................1111 USING THE IN-CAB CONTROL PANEL............................................................................................1112 Raising the Ladder....................................................................................................1112 Lowering the Ladder...................................................................................................1113 USING THE GROUND LEVEL CONTROL BOX........................................................................................1114 Raising the Ladder....................................................................................................1114 Lowering the Ladder...................................................................................................1114 POWER PACK OPERATION......................................................................................................1115 MAINTENANCE...............................................................................................................1119 Safety During Maintenance.............................................................................................1119 Unplanned Ladder Movements............................................................................................1119 Automatic Ladder Raising..............................................................................................1119 Automatic Accumulator Recharging (Ladder in UP position)..............................................................1120 PREVENTIVE MAINTENANCE PROCEDURES.........................................................................................1121 Daily Inspection......................................................................................................1121 250 Hour Inspection...................................................................................................1121 5000 Hour Inspection..................................................................................................1121 SERVICING.................................................................................................................1122 Check Reservoir Oil Level.............................................................................................1122 Changing RLS Fluid....................................................................................................1122 Cleaning the RLS......................................................................................................1123 RLS DIAGNOSTICS...........................................................................................................1123 Description of Diagnostics Features...................................................................................1123 Continuous System Monitoring..........................................................................................1124 Historic System Data Review...........................................................................................1125 Comms Integrity Monitoring............................................................................................1125 Log and Service Information...........................................................................................1125 System Event Logs.....................................................................................................1126 SECURITY ACCESS LEVELS....................................................................................................1127 Access Level 1 – NONE.................................................................................................1127 Access Level 2 – RESTRICTED...........................................................................................1127 Access Level 3 – COMPLETE.............................................................................................1127 User Access Privileges................................................................................................1128 USER ID – PASSWORD........................................................................................................1129 Sequential Field Value Selection Options..............................................................................1129 Password Character Table..............................................................................................1129 USER ID – NEW USER SETUP..................................................................................................1130 SYSTEM FAULTS.............................................................................................................1130 Fault Type 1: Communications error....................................................................................1131 Fault Type 2: 10A/15A fuse blown......................................................................................1131 Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected.............................................1132 Fault Type 8: Power pack recharge too long............................................................................1132 Fault Type 9: Inhibit relay fail......................................................................................1133 Fault Types 10, 11: Light/Siren relay failure.........................................................................1133 Fault Type 12: Ladder came off upper limit............................................................................1134 Fault Type 13: Ladder did not reach limit.............................................................................1134 Fault Type 14: Ladder stayed on limit.................................................................................1135 Fault Type 15: Low oil level..........................................................................................1135 Fault Type 16: System voltage over 18V during movement................................................................1136 Fault Type 17: System voltage under 18V...............................................................................1136 Fault Type 18: System voltage over 31V................................................................................1137 Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped)........................................1137 Fault Type 21: Accumulator recharge > than once/hour..................................................................1138 Fault Type 22: System raised by park brake............................................................................1138 Fault Types 23, 24: Levels 1 and 2 service overdue....................................................................1139 Fault Type 25: Levels 1 and 2 service complete........................................................................1139 DATA MANAGEMENT...........................................................................................................1140 Log Files.............................................................................................................1140 Generating Reports....................................................................................................1141 MENU DIAGRAMS.............................................................................................................1147 Controller Config.....................................................................................................1147 Contact Information...................................................................................................1147 Show Recent Logs......................................................................................................1147 System Settings.......................................................................................................1147 Upload Logs to USB....................................................................................................1147 Diagnostics...........................................................................................................1147 SECTION M33 CAMERA SYSTEM.........................................................................................................1155 CAMERA SYSTEM.................................................................................................................1156 CAMERA SYSTEM.............................................................................................................1156 General...............................................................................................................1156 Operation.............................................................................................................1156 Camera Switch.........................................................................................................1157 CAMERA MONITOR............................................................................................................1158 General...............................................................................................................1158 CAMERA CONTROLLER.........................................................................................................1159 General...............................................................................................................1159 Removal...............................................................................................................1159 Installation..........................................................................................................1159 Camera Controller Connector Pins......................................................................................1159 CAMERA SWITCHER...........................................................................................................1160 General...............................................................................................................1160 Removal...............................................................................................................1160 Installation..........................................................................................................1160 SETUP AND CHECKOUT PROCEDURE..............................................................................................1161 General...............................................................................................................1161 STEP 1 - Switch Function..............................................................................................1161 STEP 2 - Monitor System Settings to Default...........................................................................1161 STEP 4 - Monitor Settings - System Settings Unique....................................................................1163 STEP 4 - Monitor Settings - System Settings Unique - Cameras..........................................................1165 STEP 5 - Monitor Settings - System Settings Unique - On Screen Delay..................................................1167 STEP 6 - Monitor Settings - System Settings Unique - Standby Mode.....................................................1168 STEP 7 - Integrated Functions Check...................................................................................1169 SECTION N OPERATOR CAB................................................................................................................1171 SECTION N2 TRUCK CAB AND COMPONENTS...............................................................................................1173 TRUCK CAB AND COMPONENTS......................................................................................................1175 TRUCK CAB.................................................................................................................1175 Description...........................................................................................................1175 Removal...............................................................................................................1176 Installation..........................................................................................................1177 CAB DOOR..................................................................................................................1178 Removal...............................................................................................................1178 Installation..........................................................................................................1178 Door Jamb Bolt Adjustment.............................................................................................1179 Door Handle Plunger Adjustment........................................................................................1180 Replacing the Door Glass..............................................................................................1181 Replacing the Door Handle or Latch Assembly...........................................................................1185 Replacing the Door Window Regulator...................................................................................1186 Replacing the Door and Door Hinge Seal................................................................................1187 Replacing the Door Opening Seal.......................................................................................1187 GLASS REPLACEMENT (Adhesive-Bonded Windows)...............................................................................1188 Recommended Tools and Supplies........................................................................................1188 Replacement Procedure.................................................................................................1188 WINDSHIELD AND REAR GLASS.................................................................................................1189 Removal...............................................................................................................1189 Installation..........................................................................................................1190 SECTION N3 CAB COMPONENTS.........................................................................................................1191 CAB COMPONENTS................................................................................................................1193 WINDSHIELD WIPERS.........................................................................................................1193 WIPER MOTOR...........................................................................................................1193 Removal...........................................................................................................1193 Installation......................................................................................................1193 WIPER ARM.............................................................................................................1193 Removal...........................................................................................................1193 Installation......................................................................................................1194 WIPER LINKAGE.........................................................................................................1194 Removal...........................................................................................................1194 Installation......................................................................................................1194 WINDSHIELD WASHER.........................................................................................................1195 Operation.............................................................................................................1195 Service...............................................................................................................1195 OPERATOR SEAT (STANDARD SEAT).............................................................................................1196 Adjustment............................................................................................................1196 Inspection............................................................................................................1197 Removal...............................................................................................................1197 Installation..........................................................................................................1197 Replacing the Seat Compressor.........................................................................................1198 PASSENGER SEAT (STANDARD SEAT)............................................................................................1203 Inspection............................................................................................................1203 Removal...............................................................................................................1203 Installation..........................................................................................................1203 SEAT BELT REPLACEMENT (STANDARD SEATS - PC3230)...........................................................................1204 Removal...............................................................................................................1204 Installation..........................................................................................................1204 SEAT BELT REPLACEMENT (STANDARD SEATS - 58E-57-00500).....................................................................1206 Removal...............................................................................................................1206 Installation..........................................................................................................1206 OPERATOR SEAT (OPTIONAL SEAT).........................................................................................1208 Seat Belts........................................................................................................1208 Adjustment........................................................................................................1208 PASSENGER SEAT (OPTIONAL SEAT)........................................................................................1209 Seat Belts........................................................................................................1209 Adjustment........................................................................................................1209 SEAT BELT REPLACEMENT (OPTIONAL SEATS)....................................................................................1210 General...............................................................................................................1210 Removal...............................................................................................................1210 SECTION N4 HEATER / AIR CONDITIONER...............................................................................................1215 HEATER/AIR CONDITIONER........................................................................................................1217 OPERATION.................................................................................................................1217 Fan Speed Control Knob................................................................................................1217 Temperature Control Knob..............................................................................................1217 Air Flow Directional Knob.............................................................................................1218 Heater/Air Conditioner Vents..........................................................................................1218 COMPONENTS................................................................................................................1218 Fuse and Circuit Breaker..............................................................................................1218 Relays................................................................................................................1218 Heater Core...........................................................................................................1219 Fan Motor And Speed Control...........................................................................................1219 Actuators.............................................................................................................1219 Cab Air Filter........................................................................................................1219 ENVIRONMENTAL IMPACT OF AIR CONDITIONING..................................................................................1222 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.................................................................................1222 PRINCIPLES OF REFRIGERATION...............................................................................................1222 Air Conditioning......................................................................................................1222 Refrigeration - The Act Of Cooling....................................................................................1223 The Refrigeration Cycle...............................................................................................1223 AIR CONDITIONER SYSTEM COMPONENTS.........................................................................................1224 Compressor (Refrigerant Pump).........................................................................................1224 Service Valves........................................................................................................1224 Condenser.............................................................................................................1224 Receiver-Drier........................................................................................................1224 Expansion Block Valve.................................................................................................1225 Accumulator...........................................................................................................1225 Evaporator............................................................................................................1225 ELECTRICAL CIRCUIT........................................................................................................1226 Thermostat............................................................................................................1226 Compressor Clutch.....................................................................................................1226 Trinary™ Switch.......................................................................................................1227 AIR CONDITIONING SYSTEM SERVICING WARNINGS................................................................................1228 SERVICE TOOLS AND EQUIPMENT...............................................................................................1229 Recovery/Recycle Station..............................................................................................1229 Leak Detector.........................................................................................................1229 Manifold Gauge Set....................................................................................................1230 Installing Manifold Gauge Set.........................................................................................1231 Purging Air From Service Hoses........................................................................................1231 Service Valves........................................................................................................1232 Vacuum Pump...........................................................................................................1232 SYSTEM PERFORMANCE TEST...................................................................................................1233 SYSTEM OIL................................................................................................................1234 Handling and Reusing PAG Oil..........................................................................................1234 Oil Quantity..........................................................................................................1234 Checking System Oil...................................................................................................1234 REFRIGERANT...............................................................................................................1235 Recycled Refrigerant..................................................................................................1235 Reclaimed Refrigerant.................................................................................................1235 Refrigerant Quantity..................................................................................................1236 R-134a Refrigerant Containers.........................................................................................1236 SYSTEM LEAK TESTING.......................................................................................................1236 Electronic Leak Detector..............................................................................................1237 Tracer Dyes...........................................................................................................1237 Soap and Water........................................................................................................1237 RECOVERING AND RECYCLING THE REFRIGERANT..................................................................................1237 Draining Oil from the Previous Recovery Cycle.........................................................................1237 Performing the Recovery Cycle.........................................................................................1237 Performing the Recycling Procedure....................................................................................1238 Evacuating and Charging the A/C System................................................................................1238 SYSTEM REPAIR.............................................................................................................1238 System Flushing.......................................................................................................1238 COMPONENT REPLACEMENT.....................................................................................................1239 Hoses and Fittings....................................................................................................1239 Lines.................................................................................................................1239 Expansion Valve.......................................................................................................1239 Receiver-Drier........................................................................................................1239 Thermostat............................................................................................................1239 Compressor............................................................................................................1240 Accumulator...........................................................................................................1240 Clutch................................................................................................................1240 EVACUATING THE SYSTEM.....................................................................................................1241 CHARGING THE A/C SYSTEM...................................................................................................1242 TROUBLESHOOTING...........................................................................................................1243 Preliminary Checks....................................................................................................1243 Diagnosis Of Gauge Readings And System Performance....................................................................1243 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................................................................1244 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM................................................................................1250 SECTION N5 OPERATOR CAB AND CONTROLS..............................................................................................1251 OPERATOR CAB AND CONTROLS.....................................................................................................1254 STEERING COLUMN...........................................................................................................1255 Removal...............................................................................................................1255 Inspection............................................................................................................1255 Installation..........................................................................................................1256 STEERING WHEEL............................................................................................................1256 Removal...............................................................................................................1256 Installation..........................................................................................................1256 STEERING WHEEL AND CONTROLS...............................................................................................1258 Horn Button...........................................................................................................1258 Tilt / Telescope Lever................................................................................................1258 Multi-Function Turn Signal Switch.....................................................................................1258 DYNAMIC RETARDING.........................................................................................................1259 Retarder Lever........................................................................................................1259 Brake/Retarder Pedal..................................................................................................1259 Throttle/Accelerator Pedal............................................................................................1259 GRADE/SPEED CHART.........................................................................................................1260 OVERHEAD PANEL AND DISPLAYS...............................................................................................1261 CENTER CONSOLE............................................................................................................1262 Directional Control Lever.............................................................................................1262 Override/Fault Reset Switch...........................................................................................1263 Engine Shutdown Switch................................................................................................1263 Window Control Switches...............................................................................................1263 Hoist Control Lever...................................................................................................1263 Retarder Speed Control (RSC) Adjustment Dial..........................................................................1264 Retarder Speed Control (RSC) Switch...................................................................................1264 Data Store Button.....................................................................................................1265 KOMTRAX Plus Snapshot In Progress Light...............................................................................1265 Link Energized Light..................................................................................................1265 Service Engine Light..................................................................................................1265 12V Auxiliary Power Outlets...........................................................................................1265 Fire Suppression Control Outlet.......................................................................................1265 Communication Radio Outlet............................................................................................1265 DIAGNOSTIC PORTS..........................................................................................................1265 KOMTRAX Plus Diagnostic Port..........................................................................................1265 Interface Module (IM) Diagnostic Port.................................................................................1265 Payload Meter Diagnostic Port.........................................................................................1265 Truck Control Interface (TCI) Diagnostic Port.........................................................................1265 Propulsion System Controller (PSC) Diagnostic Port....................................................................1265 Engine Diagnostic Port (CENSE)........................................................................................1265 Engine Diagnostic Port (QUANTUM)......................................................................................1265 INSTRUMENT PANEL..........................................................................................................1266 Control Symbols.......................................................................................................1266 Key Switch............................................................................................................1268 Rotating Beacon Light Switch (optional)...............................................................................1268 Heated Mirror Switch (optional).......................................................................................1268 AC Drive System Rest Switch...........................................................................................1268 Wheel Brake Lock Switch...............................................................................................1269 Hazard Warning Light Switch...........................................................................................1269 Heater/Air Conditioner Vents..........................................................................................1269 Engine Oil Pressure Gauge.............................................................................................1269 Right Turn Signal Indicator...........................................................................................1269 Digital Tachometer....................................................................................................1269 High Beam Indicator...................................................................................................1269 Speedometer/Payload Meter Display.....................................................................................1269 Left Turn Signal Indicator............................................................................................1270 Coolant Temperature Gauge.............................................................................................1270 Lamp Check Switch.....................................................................................................1270 Light Switch (3-Way)..................................................................................................1270 Ladder Light Switch...................................................................................................1270 Backup Light Switch...................................................................................................1270 Fog Light Switch......................................................................................................1271 Payload Meter Switch..................................................................................................1271 Panel Illumination Light Dimmer Switch................................................................................1271 Hydraulic Oil Temperature Gauge.......................................................................................1271 Engine Hourmeter......................................................................................................1271 Fuel Gauge............................................................................................................1271 OVERHEAD STATUS / WARNING INDICATORS......................................................................................1272 A1. High Brake Oil Temperature........................................................................................1273 B1. Low Steering Pressure.............................................................................................1273 C1. Low Accumulator Precharge Pressure................................................................................1274 D1. Not used..........................................................................................................1274 E1. Low Brake Pressure................................................................................................1274 A2. Low Hydraulic Tank Level..........................................................................................1274 B2. Low Automatic Lubrication System Pressure.........................................................................1274 C2. Circuit Breaker Tripped...........................................................................................1274 D2. Hydraulic Oil Filter Monitor......................................................................................1275 E2. Low Fuel..........................................................................................................1275 A3. Parking Brake.....................................................................................................1275 B3. Service Brake.....................................................................................................1275 C3. Body Up...........................................................................................................1275 D3. Dynamic Retarding.................................................................................................1275 E3. Stop Engine.......................................................................................................1276 A4. Cranking Motor Failure............................................................................................1276 B4. Backup Lights.....................................................................................................1276 C4. Engine Shutdown Timer.............................................................................................1276 D4. Retard Speed Control (RSC) Indicator..............................................................................1276 E4. Check Engine......................................................................................................1276 A5. No Power..........................................................................................................1277 B5. Propulsion System Warning.........................................................................................1277 C5. Propulsion System Temperature.....................................................................................1277 D5. System/Component Failure..........................................................................................1277 E5. Battery Charging System Failure...................................................................................1277 A6. No Propel.........................................................................................................1277 B6. Propel System At Rest.............................................................................................1277 C6. Propel System Not Ready...........................................................................................1278 D6. Reduced Propulsion................................................................................................1278 E6. Retard At Continuous Level........................................................................................1278 REAR AXLE LIGHT BAR.......................................................................................................1279 Backup Lights.........................................................................................................1279 Retard Lights.........................................................................................................1279 Brake Lights..........................................................................................................1279 Backup Alarm..........................................................................................................1279 KOMTRAX PLUS..............................................................................................................1280 Operation.............................................................................................................1280 Interface Module......................................................................................................1282 Basic Precautions.....................................................................................................1282 KOMATSU WIRELESS BRIDGE (Optional)........................................................................................1283 General Information...................................................................................................1283 Communication Setup...................................................................................................1283 Switching to the KWB_SETUP Network....................................................................................1283 Setting the Computer Subnet Mask and IP Address.......................................................................1284 Properties............................................................................................................1284 Setting Up the KWB....................................................................................................1285 Adding Encryption.....................................................................................................1285 Final Computer Settings...............................................................................................1285 Data Downloading......................................................................................................1286 Resetting the KWB.....................................................................................................1286 KWB Lights............................................................................................................1286 SECTION P LUBRICATION AND SERVICE.....................................................................................................1287 SECTION P2 LUBRICATION AND SERVICE................................................................................................1289 LUBRICATION AND SERVICE.......................................................................................................1291 GENERAL...................................................................................................................1291 SERVICE CAPACITIES........................................................................................................1291 HYDRAULIC TANK SERVICE....................................................................................................1291 Adding Oil............................................................................................................1291 COOLING SYSTEM SERVICE....................................................................................................1292 Radiator Filling Procedure............................................................................................1292 Coolant Specifications................................................................................................1292 Unacceptable Practices................................................................................................1292 WHEEL MOTOR SERVICE.......................................................................................................1292 RESERVE OIL TANK SERVICE..................................................................................................1293 Filling the Reserve Oil Tank (Remote Fill)............................................................................1293 Inline Screen.........................................................................................................1293 QUICK FILL SERVICE CENTER.................................................................................................1294 LUBRICATION CHART.........................................................................................................1295 10 HOUR (DAILY) INSPECTIONS...............................................................................................1296 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................1298 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1298 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1298 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1301 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................1303 5000 HOUR MAINTENANCE CHECKS..............................................................................................1303 SECTION P3 AUTOMATIC LUBRICATION SYSTEM...........................................................................................1305 AUTOMATIC LUBRICATION SYSTEM..................................................................................................1307 GENERAL DESCRIPTION.......................................................................................................1307 SYSTEM COMPONENTS.........................................................................................................1309 Filter................................................................................................................1309 Hydraulic Motor and Pump..............................................................................................1309 Grease Reservoir......................................................................................................1309 Pressure Reducing Valve...............................................................................................1309 Flow Control Valve....................................................................................................1309 Solenoid Valve........................................................................................................1309 Vent Valve............................................................................................................1309 Lubrication Cycle Timer...............................................................................................1309 Over Pressure Cut Off Switch..........................................................................................1309 Grease Pressure Failure Switch........................................................................................1309 Injectors.............................................................................................................1309 Relief Valve (unloader valve).........................................................................................1309 SYSTEM OPERATION..........................................................................................................1310 Normal Operation......................................................................................................1310 Lubricant Required For System.........................................................................................1311 System Priming........................................................................................................1311 Filter Assembly.......................................................................................................1311 LUBRICANT PUMP............................................................................................................1312 Pump Housing Oil Level................................................................................................1312 Pump Pressure Control.................................................................................................1312 INJECTORS (SL-1 Series “H”)...............................................................................................1313 Injector Specifications...............................................................................................1313 Injector Adjustment...................................................................................................1313 INJECTOR OPERATION....................................................................................................1314 PREVENTIVE MAINTENANCE PROCEDURES.........................................................................................1315 Daily Lubrication System Inspection...................................................................................1315 250 Hour Inspection...................................................................................................1315 1000 Hour Inspection..................................................................................................1315 SYSTEM CHECKOUT...........................................................................................................1316 Lubrication Controller Check..........................................................................................1316 Lubrication Controller Components.....................................................................................1316 Lubrication Controller Adjustment.....................................................................................1316 SYSTEM TROUBLESHOOTING CHART..................................................................................................1318 SECTION Q ALPHABETICAL INDEX..........................................................................................................1321 SECTION R SYSTEM SCHEMATICS...........................................................................................................1325 HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC.......................................................................1327 HYDRAULIC BRAKE SYSTEM SCHEMATIC..................................................................................................1328 ELECTRICAL SCHEMATICS.............................................................................................................1329
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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Brycen Gustavo –