Komatsu 980E-5SU DUMP TRUCK Shop Manual CEBM035300 – PDF DOWNLOAD

Description

Komatsu 980E-5SU DUMP TRUCK Shop Manual CEBM035300 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 980E-5SU DUMP TRUCK Shop Manual CEBM035300 – PDF DOWNLOAD

Language : English
Pages :1376
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 980E-5SU DUMP TRUCK Shop Manual CEBM035300 – PDF DOWNLOAD

SERIAL NUMBERS 930E-5SE
A50001 and up

Foreword

This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck.

• All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.
• For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout.
• All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 Nm (100 ft lb).
• All torque specifications have ±10% tolerance unless otherwise 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. 960E).
• 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, refer to the Operation and Maintenance Manual. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW.
• The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload. To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck components.

TABLE OF CONTENTS:

Komatsu 980E-5SU DUMP TRUCK Shop Manual CEBM035300 – PDF DOWNLOAD

SERIAL NUMBERS 930E-5SE
A50001 and up

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 23
Foreword 26
How to read the shop manual 27
Composition of shop manual 27
Revision and distribution 27
Symbols 28
General safety 29
Safety rules 29
Safety features 29
Fire extinguisher and first aid kit 29
Clothing and personal items 29
Leaving the operator seat 30
Mounting and dismounting 30
Fire prevention for fuel and oil 30
Precautions with high temperature fluids 31
Asbestos dust hazard prevention 31
Prevention of injury by work equipment 31
Unauthorized modification 31
Precautions when using ROPS 31
Precautions for attachments 32
Precautions for starting the truck 32
Precautions before operating the truck 32
Safety at the worksite 32
Fire prevention 33
Ventilation in enclosed areas 33
Preparing for operation 33
Mirrors, windows and lights 33
In operator cab (before starting the engine) 33
Seat Belts 33
Precautions while operating the truck 34
When starting the engine 34
General truck operation 34
Ensuring good visibility 34
Traveling 35
Traveling in reverse 35
Traveling on slopes 35
Operating on snow or ice 35
Avoid damage to dump body 35
Driving near high voltage cables 36
When dumping 36
When loading 36
Working on loose ground 36
Parking the truck 37
Towing 37
Working near batteries 38
Battery hazard prevention 38
Starting with jumper cables 39
Jump starting with receptacles 39
Precautions before performing service 40
Warning tag 40
Stopping the engine 40
Proper tools 40
Use of tie-off anchor during maintenance and repair 41
Tie-off anchor installation 41
Securing the dump body 42
Jack point locations 43
Precautions while performing service 44
Keep the truck clean 44
Attachments 44
Working under the truck 44
Rotating fan and belts 44
Adding fuel or oil 44
Use of lighting 44
Radiator coolant level 45
Precautions with the battery 45
Precautions with high pressure oil 45
Handling high pressure hoses 45
Precautions when performing maintenance near high temperature or high pressure 45
Waste materials 45
Tires 46
Inspection 46
Maintenance 46
Storage 47
Handling 48
Precautions for performing repairs 49
Engine shutdown procedure after AC drive system failure 49
Precautions for welding on the truck 50
Control cabinet capacitor discharge system 51
Handling electrical equipment and hydraulic components 53
Points to remember when handling electrical equipment 53
Points to remember when handling hydraulic equipment 59
Actions taken to meet exhaust gas regulations 61
About DEF 61
Precautions for diesel exhaust fluid (DEF) 62
About DEF 62
Precautions for handling DEF 62
Precautions for storing DEF 62
Precautions for disposing of DEF 63
Crystallization management 63
Precautions for cold weather operation 63
Standard tightening torques 64
Effect of special lubricants on fasteners and standard torque values 64
Suggested sources for rust preventive grease 64
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 65
SAE grade 9 capscrews 66
Class 109 capscrews and class 10 nuts 66
Standard tightening torques for fittings 67
Standard tightening torques for clamps 69
Conversion tables 70
Common conversion multipliers 70
01 Specification 75
Specification and technical data 75
Specification drawing 77
Specifications 78
Weight table 80
Fuel, coolant and lubricants 81
Suspension cylinder oil and nitrogen specifications 82
Wheel motor oil specifications 82
10 Structure and functions 85
Steering circuit 85
Steering circuit operation 86
Steering circuit components 91
Steering control unit 91
High pressure filter 91
Steering accumulators 91
Bleeddown manifold 92
Steering accumulator bleeddown solenoid 92
Quick disconnect ports 92
Flow amplifier 92
Steering/brake pump operation 93
High altitude operation 93
Neutral position 94
Full pump volume 95
Half pump volume 95
Flow amplifier operation 96
No steer 96
Steering left 98
Steering right 100
No steer, external shock load 102
Hoist circuit 105
Hoist circuit operation 106
Hoist circuit components 106
Hydraulic tank 106
Hoist pump 106
High pressure filters 106
Hoist valve 109
Inlet sections 109
Tank ports (front) spool section 109
Work ports (rear) spool section 110
Hoist pilot valve 110
Hoist limit solenoid 111
Pilot operated check valve 111
Overcenter manifold 111
Hoist pilot valve operation 112
Float position with body down 112
Power up operation 114
Hold operation 116
Power down operation 118
Float operation with body up 120
Brake circuits 123
General information 125
Service brake circuit operation 128
Secondary braking and auto apply 129
Parking brake circuit operation 130
Normal operation (key start switch ON, engine on) 130
Wheel brake lock circuit operation 131
Brake warning circuit operation 131
Electrical system, 24 volt 133
Battery supply system 135
Batteries 135
24VDC auxiliary battery receptacles 135
Isolation box 136
Ground level shutdown switch 136
Battery disconnect switches 136
Propel lockout lever 136
System busy light 136
LED lights 136
Engine starting system with prelube 137
Prelube operation 137
Cranking operation 138
Auxiliary control cabinet components 139
VEC blocks 140
24VDC to 12VDC converter 140
Circuit breakers 140
Engine service light timer 140
Ground terminals 140
24VDC power terminals 140
Relays 141
Body-up switch 142
Hoist limit switch 143
Heating/air conditioning (HVAC) system 145
Basic air conditioning system operation 147
HVAC components 149
Control panel 149
Water valve 149
Expansion valve 149
Actuators 149
Blower 149
Heater core 149
Evaporator core 149
Cab air temperature sensor 149
ECU module 149
Air filters 151
Compressor (refrigerant pump) 151
Compressor clutch 151
Trinary™ switch 152
Receiver-drier 152
Condenser 152
Accumulator 152
Automatic lubrication (auto lube) system 155
General information 157
System operation 158
Engine emissions aftertreatment system 161
About emissions aftertreatment 164
DEF injection system 164
DEF heating system 164
Sensors 164
Exhaust system cleaning 165
Propel lockout precaution 165
Inducement strategy 165
20 Standard value table 167
Standard value table 167
Standard value table for truck 169
30 Testing and adjusting 175
Steering, hoist, brake cooling and auxiliary hydraulic systems 175
Hydraulic system bleeddown procedure 177
Hydraulic system vacuum procedure 179
General information on system checkout 180
Hydraulic system checkout procedures 180
Required equipment 180
Preliminary steps 181
Hydraulic system flushing procedure 181
Flow amplifier adjustment 185
Steering pump unloader valve adjustment 186
Auxiliary accumulator pressure verification 186
System diagnostics 187
Hoist pilot relief valve adjustment 189
Hoist counterbalance valve adjustment 190
Final steps 191
Oil cleanliness check 191
Hydraulic system checkout data sheet 192
Toe-in adjustment 195
Hoist cylinder leakage test 196
Steering cylinder leakage test 196
Brake system 199
General information on system checkout 201
Brake system checkout procedures 201
Required equipment 201
Bleeddown procedure 201
Preliminary steps 204
Service brake checkout (front and rear) 205
Brake lock system checkout 206
Low brake pressure and auto apply checkout 206
Service brake checkout (left and right) 208
Parking brake checkout 209
Parking brake control logic checkout 209
Brake lock control logic checkout 211
Brake system checkout data sheet 214
Brake piston leakage test 223
Brake seal pressure test 223
Oil separator seal pressure test 223
Method 1 223
Method 2 224
Wet disc brake bleeding procedure 224
Parking brake bleeding procedure 225
Service brake disc wear inspection 226
Parking brake disc wear inspection 227
Accumulators and suspensions 229
Accumulator charging and storage 231
Temperature during precharge 231
Bladder accumulator charging procedure 232
Precharge maintenance 234
Bladder accumulator storage procedure 234
Bladder storage 234
Installing a bladder accumulator from storage 235
Bladder accumulator leak testing 235
Piston accumulator charging procedure 236
Piston accumulator storage 239
Piston accumulator leak testing 240
Checking for improper suspension charge on operating trucks 241
Suspension oil change recommendations 242
Suspension oiling and charging procedures 243
Required equipment 243
Installing the charging kit 244
Removing the charging kit 244
Support blocks for oiling and charging dimensions 245
Front suspensions 248
TOP FILL METHOD 249
PRESSURE FILL METHOD 249
Rear suspensions 251
TOP FILL METHOD 253
PRESSURE FILL METHOD 253
Suspension pressure test 256
Electrical systems 259
General information on system checkout 261
Truck shutdown procedure 262
AC drive system 263
Drive system control group components 263
Required software and tools 263
Electrical system checkout procedures 264
Visual inspection 264
Resistance checks 264
Voltage checks 265
Truck function checks 267
Interface module (IM) checks 268
KOMTRAX Plus II checks 268
Payload meter (PLM) checks 268
Drive system checks 269
Engine delayed shutdown Smart Timer check 269
Body hoist limit switch check 269
Electrical checkout sheet 270
Interface module 2 (IM2) 275
Required tools 277
Programming the IM2 277
Updating the software 277
Configuring the IM2 278
Viewing IM2 real-time data 278
Interface module checkout procedures 279
Checking for IM fault codes 279
Checking digital inputs to the IM 279
Checking analog inputs to the IM 282
Checking serial communication to the IM 282
Checking outputs from the IM 283
IM checkout sheet 284
Payload meter IV 289
Payload meter IV software and tools 291
Payload meter IV system configuration 291
Connecting to the payload meter IV web server 291
Configuring a static IP address 291
Payload meter IV software installation 293
Inclinometer calibration and clean truck tare 294
Payload meter IV checkout procedure 294
PLM IV system checkout data sheet 300
Downloading PLM IV data and possible errors 301
KOMTRAX Plus II 305
Required software and tools 307
Ethernet connection to KOMTRAX Plus II controller 307
KOMTRAX Plus II configuration 309
GPS connection test 311
Iridium satellite system opening 313
Data download over ethernet connection for KOMTRAX Plus II initialization 316
Komatsu wireless bridge (KWB) 319
General information 321
Required software and tools 321
Configuring the Bullet wireless radio 322
Installing the Bullet wireless radio 325
Configuring the NanoStation access point 326
Testing the connection 329
Changing a service computer’s IP address 330
Cab air conditioning 333
General information 335
Service tools and equipment 336
Recovery/recycle station 336
Leak detector 336
Manifold gauge set 337
Service valves 338
Vacuum pump 338
Detecting leaks 339
System performance test 340
Checking system oil 341
System flushing 342
Installing the manifold gauge set 343
Purging air from the service hoses 344
Recovering and recycling refrigerant 345
Draining oil from previous recovery cycle 346
Recovery cycle 346
Recycling procedure 346
Evacuating the air conditioning system 347
Charging the air conditioning system 348
Automatic lubrication (auto lube) system 351
Priming the system 353
Checkout procedure 355
Adjusting the lubrication cycle timing 356
Trucks with Interface Module 1 356
Trucks with Interface Module 2 356
KomVision 359
Requirements 361
Initial setup 361
Checkout data sheet 368
Calibration sheets 373
Layout and assemblage 373
Unfolding a calibration sheet 376
Folding a calibration sheet 377
Placement of calibration sheets 378
Camera calibration procedures 380
Automatic 6 camera calibration 380
Manual 6 camera calibration 384
1 camera calibration 387
Radar setting procedure 390
Tire monitoring system 395
Tire monitoring system software and tools 397
Tire monitoring system configuration 397
Connecting to the tire monitoring system web server 397
Configuring a static IP address 397
Tire monitoring system software installation 399
Tire monitoring system checkout procedure 400
Field Troubleshooting 400
Ethernet troubleshooting 400
Tire monitoring system configuration 401
CAN RPC Troubleshooting 401
Resetting the tire monitoring system 401
Tire monitoring system checkout data sheet 402
40 Troubleshooting 405
Fuse, diode and relay locations 405
Vehicle Electrical Center (VEC-89) 407
Vehicle Electrical Center (VEC-90) 409
Vehicle Electrical Center (VEC-91) 411
Vehicle Electrical Center (VEC-92) 413
Rear Terminal Mini-fuse and Relay (RTMR3) 414
Rear Terminal Mini-fuse and Relay (RTMR4) 415
Circuit breakers 416
Troubleshooting by fault code, Part 1 419
Fault Code A001 422
Fault Code A002 423
Fault Code A003 424
Fault Code A004 425
Fault Code A005 426
Fault Code A006 427
Fault Code A007 428
Fault Code A008 429
Fault Code A009 430
Related circuit diagram 430
Fault Code A010 431
Related circuit diagram 431
Fault Code A011 432
Fault Code A013 433
Fault Code A014 434
Fault Code A016 435
Fault Code A017 436
Fault Code A018 437
Fault Code A019 438
Fault Code A022 439
Fault Code A100 440
Related circuit diagram 440
Fault Code A101 441
Fault Code A103 442
Fault Code A104 443
Fault Code A105 444
Fault Code A109 445
Fault Code A111 446
Fault Code A115 447
Fault Code A117 448
Fault Code A118 449
Fault Code A123 450
Fault Code A124 451
Fault Code A125 452
Fault Code A126 453
Fault Code A127 454
Fault Code A128 455
Fault Code A139 456
Troubleshooting by fault code, Part 2 459
Fault Code A145 462
Fault Code A146 463
Fault Code A152 464
Fault Code A153 465
Fault Code A154 466
Fault Code A155 467
Fault Code A158 468
Fault Code A166 469
Fault Code A167 470
Fault Code A168 471
Fault Code A169 472
Fault Code A170 473
Fault Code A171 474
Fault Code A172 475
Fault Code A173 476
Fault Code A184 477
Fault Code A190 478
Fault Code A193 479
Fault Code A194 480
Fault Code A195 481
Fault Code A196 482
Fault Code A197 483
Fault Code A198 484
Fault Code A199 485
Fault Code A200 486
Fault Code A201 487
Fault Code A202 488
Fault Code A203 489
Fault Code A204 490
Fault Code A205 491
Fault Code A206 492
Fault Code A207 493
Fault Code A213 494
Fault Code A214 495
Fault Code A215 496
Fault Code A216 497
Fault Code A223 498
Fault Code A230 499
Fault Code A231 500
Fault Code A233 501
Fault Code A235 502
Fault Code A236 503
Fault Code A237 504
Fault Code A238 505
Fault Code A239 507
Related circuit diagram 508
Fault Code A240 509
Fault Code A242 510
Fault Code A243 511
Fault Code A244 512
Fault Code A245 513
Fault Code A246 514
Troubleshooting by fault code, Part 3 517
Fault Code A247 519
Fault Code A248 520
Fault Code A249 521
Fault Code A250 522
Fault Code A251 523
Fault Code A252 524
Fault Code A253 525
Fault Code A256 526
Fault Code A257 527
Fault Code A258 528
Fault Code A260 529
Fault Code A261 530
Fault Code A262 531
Fault Code A264 532
Fault Code A265 533
Fault Code A266 534
Fault Code A267 535
Fault Code A268 536
Fault Code A270 537
Fault Code A271 538
Related circuit diagram 539
Fault Code A272 540
Fault Code A273 541
Fault Code A274 542
Fault Code A275 543
Fault Code A277 544
Fault Code A278 545
Fault Code A279 546
Fault Code A280 547
Fault Code A281 548
Fault Code A282 549
Fault Code A283 550
Fault Code A284 551
Fault Code A285 552
Fault Code A286 553
Fault Code A292 554
Troubleshooting by fault code, Part 4 557
Fault Code A303 560
Fault Code A304 561
Fault Code A305 562
Fault Code A307 563
Fault Code A309 564
Fault Code A310 565
Fault Code A311 566
Fault Code A312 567
Fault Code A313 568
Fault Code A315 569
Fault Code A316 570
Fault Code A317 571
Fault Code A318 572
Fault Code A328 573
Fault Code A332 574
Fault Code A333 575
Fault Code A334 576
Fault Code A335 577
Fault Code A337 578
Fault Code A338 579
Fault Code A339 580
Fault Code A340 581
Fault Code A341 582
Fault Code A342 583
Fault Code A343 584
Fault Code A344 585
Fault Code A345 586
Fault Code A346 587
Fault Code A347 588
Fault Code A348 589
Fault Code A349 590
Fault Code A350 591
Fault Code A351 592
Fault Code A352 593
Fault Code A353 594
Fault Code A354 595
Fault Code A355 596
Fault Code A356 597
Fault Code A357 598
Fault Code A358 599
Fault Code A359 600
Fault Code A360 601
Fault Code A361 602
Fault Code A362 603
Fault Code A363 604
Fault Code A364 605
Fault Code A365 606
Fault Code A366 607
Troubleshooting by fault code, Part 5 609
Fault Code A400 612
Fault Code A401 613
Fault Code A402 614
Fault Code A403 615
Fault Code A404 616
Fault Code A405 617
Fault Code A406 618
Fault Code A407 619
Fault Code A408 620
Fault Code A409 621
Fault Code A410 622
Fault Code A411 623
Fault Code A412 624
Fault Code A413 625
Fault Code A414 626
Fault Code A415 627
Fault Code A416 628
Fault Code A417 629
Fault Code A418 630
Fault Code A419 631
Fault Code A420 632
Fault Code A421 633
Fault Code A422 634
Fault Code A423 635
Fault Code A424 636
Fault Code A425 637
Fault Code A426 638
Fault Code A427 639
Fault Code A428 640
Fault Code A429 641
Fault Code A430 642
Fault Code A431 643
Fault Code A432 644
Fault Code A433 645
Fault Code A434 646
Fault Code A435 647
Fault Code A436 648
Fault Code A437 649
Fault Code A438 650
Fault Code A439 651
Fault Code A440 652
Fault Code A441 653
Fault Code A442 654
Fault Code A443 655
Fault Code A444 656
Fault Code A445 657
Fault Code A446 658
Fault Code A447 659
Aftertreatment system fault codes 661
Fault Code CA256 665
Fault Code CA1677 667
Fault Code CA1678 669
Fault Code CA1682 672
Fault Code CA1683 679
Fault Code CA1684 681
Fault Code CA1685 683
Fault Code CA1686 685
Fault Code CA1712 687
Fault Code CA1713 689
Fault Code CA1714 691
Fault Code CA1715 692
Fault Code CA1887 694
Fault Code CA2771 695
Fault Code CA3142 699
Fault Code CA3143 701
Fault Code CA3146 703
Fault Code CA3147 705
Fault Code CA3232 707
Fault Code CA3497 710
Fault Code CA3498 711
Fault Code CA3547 712
Fault Code CA3558 713
Fault Code CA3559 715
Fault Code CA3562 717
Fault Code CA3563 719
Fault Code CA3567 721
Fault Code CA3571 723
Fault Code CA3572 725
Fault Code CA3573 728
Fault Code CA3574 730
Fault Code CA3575 732
Fault Code CA3712 734
Fault Code CA3713 735
Fault Code CA3714 738
Fault Code CA3867 739
Fault Code CA3868 741
Fault Code CA3878 744
Fault Code CA3988 745
Fault Code CA3995 749
Fault Code CA4113 751
Fault Code CA4114 753
Fault Code CA4119 755
Fault Code CA4121 757
Fault Code CA4152 759
Fault Code CA4164 763
Fault Code CA4165 765
Fault Code CA4166 768
Fault Code CA4168 770
Fault Code CA4169 772
Fault Code CA4174 774
Fault Code CA4175 776
Fault Code CA4233 779
Fault Code CA4234 780
Fault Code CA4243 781
Fault Code CA4277 782
Fault Code CA4457 784
Fault Code CA4458 786
Fault Code CA4459 789
Fault Code CA4461 791
Fault Code CA4462 793
Fault Code CA4464 795
Fault Code CA4465 797
Fault Code CA4466 800
Fault Code CA4467 807
Fault Code CA4474 809
Fault Code CA4475 811
Fault Code CA4572 814
Fault Code CA4677 818
Fault Code CA4679 822
Fault Code CA4682 823
Fault Code CA4731 824
Fault Code CA4732 825
Fault Code CA4736 826
Fault Code CA4737 827
Fault Code CA4738 828
Fault Code CA4739 829
Fault Code CA4745 830
Fault Code CA4768 831
Fault Code CA4769 833
Fault Code CA4842 835
Fault Code CA4863 836
Fault Code CA4947 837
Fault Code CA5115 838
Fault Code CA5116 841
Fault Code CA5117 844
Fault Code CA5247 847
Fault Code CA5653 849
Fault Code CA5654 852
Fault Code CA5725 854
Fault Code CA5727 859
Fault Code CA5728 862
Fault Code CA5729 865
Fault Code CA5748 867
Fault Code CA5749 869
Fault Code CA5751 871
Fault Code CA5753 873
Fault Code CA5755 876
Fault Code CA5756 881
Fault Code CA5758 883
Fault Code CA5768 885
Fault Code CA5769 887
Fault Code CA5771 890
Fault Code CA5772 892
Fault Code CA5773 895
Fault Code CA5774 898
Fault Code CA5775 900
Fault Code CA5776 905
Fault Code CA5778 907
Fault Code CA5779 909
Fault Code CA5887 911
Fault Code CA5888 912
Fault Code CA5889 913
Fault Code CA5891 914
Fault Code CA5892 915
Fault Code CA5893 916
Fault Code CA6692 917
Fault Code CA6693 919
Fault Code CA6694 921
Fault Code CA6695 923
Fault Code CA6696 925
Fault Code CA6697 927
Fault Code CA6855 929
Fault Code CA6856 932
Steering system 935
Steering circuit troubleshooting chart 937
Steering circuit troubleshooting guidelines 939
Basic hydraulic system checks 940
System leakage check 941
Steering pump troubleshooting guide 943
Pump pressure control checks 946
Pump fails to unload 947
Pump fails to develop pressure 947
Pump slow in developing pressure 948
Pump control valve inspection and troubleshooting 949
Pump case drain check 951
Setting pump pressure controls 951
KomVision 955
KomVision fault codes 957
Automatic lubrication (auto lube) system 967
Autolube troubleshooting chart 969
Heating/air conditioning (HVAC) system 973
Control panel configurations 975
Diagnostics mode 976
Error codes 976
Advanced diagnostics 976
Firmware version 977
Additional HVAC troubleshooting chart 977
Voltage levels 979
Electronic fan clutch 981
Electronic fan clutch troubleshooting 983
Electronic fan clutch fault codes 985
50 Disassembly and assembly 987
Service tools 987
Special tool group 989
Additional service tools 990
KomVision calibration tools 991
Locally made tools 991
Wheels, spindles and rear axle 993
General precautions for tires and rims 995
Wheel stud maintenance 996
Rear outer wheel stud installation 997
Removal and installation of front wheel 998
Removal 998
Installation 999
Removal and installation of rear wheel1000
Removal1000
Installation1001
Rim components1003
Smart Rim Component Layout1003
Rim and tire service1004
Lubricants1004
Tire inflation1004
Lock ring retainer installation1004
Removing the lock ring1005
Installing the lock ring1006
Removing the tire from the front rim (5-piece rim)1007
Removing the tire from the rear outer dual rim (7-piece Smart rim)1010
Removing the tire from the rear inner dual rim (5-piece rim)1012
Preparation before assembly1013
Installing the tire on the front rim (5-piece rim)1014
Installing the tire on the rear inner dual rim (5-piece rim)1016
Installing the tire on the rear outer dual rim (7-piece Smart rim)1017
Removal and installation of front wheel hub and spindle1018
Removal1018
Spindle removal (off the truck)1024
Installation1026
Disassembly and assembly of front wheel hub and spindle1027
Cross Section View1027
Disassembly1028
Cleaning and inspection1035
Assembly1036
Wheel bearing adjustment1038
Seal assembly gap adjustment1039
Brake seal installation1040
Oil separation seal installation1041
Brake installation1042
Speed sensor installation and adjustment1046
Floating ring seal assembly and installation1048
Removal and installation of rear axle1057
Removal1057
Cleaning and inspection1059
Installation1059
Removal and installation of anti-sway bar1060
Removal1060
Installation1062
Removal and installation of pivot pin1063
Removal1063
Installation1064
Removal and installation of pivot bearing1065
Replacement criteria1065
Removal1067
Inspection1067
Installation1067
Removal and installation of pivot eye1068
Removal1068
Inspection1068
Installation1068
Removal of wheel motor1069
Preparation1069
Installation of wheel motor1071
Cleaning and inspection1071
Installation1072
Removal and installation of rear brake assembly1075
Brake system1077
Removal and installation of brake valve1079
Removal1079
Installation1080
Disassembly and assembly of brake valve/pedal assembly1081
Disassembly1081
Assembly1082
Removal and installation of dual relay valve1085
Removal1085
Installation1086
Removal and installation of brake manifold1087
Removal1087
Installation1087
Disassembly and assembly of brake manifold1088
Disassembly1088
Assembly1088
Removal and installation of piston brake accumulator1089
Removal1089
Installation1091
Disassembly and assembly of piston brake accumulator1093
Disassembly1093
Cleaning and inspection1095
Piston seal replacement1095
Assembly1096
Disassembly and assembly of front wheel brake1097
Disassembly1097
Cleaning and inspection1100
Assembly1101
Disassembly and assembly of rear wheel brake1103
Disassembly1103
Cleaning and inspection1107
Assembly1108
Brake floating ring seal assembly and installation1112
Rear hub floating ring seal assembly and installation1121
Removal and installation of parking brake1127
Removal1127
Installation1129
Disassembly and assembly of parking brake1130
Disassemble and reassemble the brake assembly on a clean, dry work surface The work surface should be wooden If the work surface is metal or concrete, use padding to prevent damage to machined surfaces Handle all parts carefully to avoid damage to1130
Disassembly1130
Cleaning and inspection1132
Cleaning and inspecting new discs1134
Assembly1135
Steering system1137
Removal and installation of steering control unit1139
Removal1139
Installation1141
Disassembly and assembly of steering control unit1142
Disassembly1142
Assembly1144
Removal and installation of steering column1147
Removal1147
Installation1148
Removal and installation of steering wheel1149
Removal1149
Installation1149
Removal and installation of bleeddown manifold1150
Removal1150
Installation1151
Removal and installation of flow amplifier1152
Removal1152
Installation1152
Removal and installation of steering cylinders and tie rod1153
Removal1153
Installation1153
Disassembly and assembly of steering cylinders1155
Disassembly1155
Cleaning and inspection1157
Assembly1157
Removal and installation of steering/brake pump1158
Removal1158
Installation1160
Removal and installation of piston steering accumulator1161
Removal1161
Installation1163
Disassembly and assembly of piston steering accumulator1165
Disassembly1165
Cleaning and inspection1167
Piston seal replacement1167
Assembly1168
Suspensions1171
General information1173
Removal and installation of front suspension1173
Preparation1173
Removal1173
Cleaning and Inspection1175
Installation1176
Disassembly and assembly of front suspension1181
Disassembly1181
Cleaning and inspection1184
Assembly1184
Removal and installation of rear suspension1186
Removal1186
Installation1189
Disassembly and assembly of rear suspension1192
Disassembly1192
Cleaning and inspection1194
Assembly1195
Hoist circuit1197
Removal and installation of hoist pump1199
Removal1199
Installation1203
Disassembly and assembly of hoist pump1204
Disassembly1204
Inspection1209
Assembly1210
Removal and installation of hoist valve1213
Removal1213
Installation1215
Disassembly and assembly of hoist valve1215
O-ring replacement1215
Disassembly of inlet section1217
Assembly of inlet section1218
Disassembly of rear spool section1219
Assembly of rear spool section1221
Disassembly of front spool section1222
Assembly of front spool section1223
Overcenter manifold service1223
Removal and installation of hoist pilot valve1224
Removal1224
Installation1224
Disassembly and assembly of hoist pilot valve1226
Disassembly1226
Cleaning and inspection1227
Assembly1227
Removal and installation of hoist cylinders1228
Removal1228
Installation1230
Disassembly and assembly of hoist cylinders1231
Disassembly1231
Cleaning and inspection1235
Installation of the quill1236
Assembly1238
Body and structures1243
Removal and installation of dump body1245
Removal1245
Inspection1246
Installation1247
Removal and installation of body pads1248
Removal1248
Installation1248
Body pad shimming procedure1249
Removal and installation of diagonal ladder/ hood and grille assembly1250
Removal1250
Installation1250
Removal and installation of RH deck1252
Removal1252
Installation1252
Removal and installation of LH deck1254
Removal1254
Installation1254
Removal and installation of fuel tank (with DEF tank)1256
Removal1256
Cleaning and inspection1256
Installation1258
Removal and installation of fuel gauge sender1258
Removal1258
Installation1258
Removal and installation of hydraulic tank1259
Removal1259
Installation1260
Removal and installation of hydraulic tank strainers1261
Removal1261
Cleaning and inspection1262
Installation1262
Operator cab1265
Removal and installation of operator cab1267
Removal1267
Installation1270
Removal and installation of cab door1270
Removal1270
Installation1271
Disassembly and assembly of cab door1272
Removing the window regulator1272
Installing the window regulator1273
Removing the door glass1274
Installing the door glass1275
Replacing the inner door seal1276
Replacing the outer door seal1276
Removing the interior door handle and door latch (earlier models)1277
Installation and removal of interior door handle and door latch (later models)1280
Adjustment of cab door1282
Door jamb bolt adjustment1282
Exterior door handle release button adjustment1284
Removal and installation of side window glass1285
Recommended tools and supplies1285
Removal1285
Installation1286
Removal and installation of windshield and rear window glass1287
Removal1287
Installation1287
Removal and installation of windshield wiper components1288
Removing the windshield wiper motor1288
Installing the windshield wiper motor1288
Removing the windshield wiper arm and linkage1289
Installing the windshield wiper arm and linkage1290
Removal and installation of cab seats1290
Removal1290
Servicing the seat1291
Installation1291
Removal and installation of seat belts1292
Removal1292
Installation1293
Power module1295
Removal and installation of power module1297
General1297
Removal1298
Installation1307
Exhaust tube installation1310
Exhaust blanket installation1310
Removal and installation of alternator1311
Removal1311
Installation1314
Removal and installation of radiator1325
Removal1325
Installation1330
Repairing the radiator1331
Internal inspection1331
External cleaning1331
Disassembly1331
Cleaning and inspection1332
Assembly1333
Pressure testing1334
Removal and installation of engine1334
Removal1334
Service1334
Installation1335
Removal and installation of electronic fan clutch1336
Removal1336
Installation1337
Removal and installation of electronic fan clutch speed sensor1337
Removal1337
Installation1337
90 Diagrams and drawings1339
Hydraulic circuit diagrams1339
Steering, hoist and brake cooling hydraulic circuit diagram1341
Brake hydraulic circuit diagram1342
Auxiliary system hydraulic circuit schematic1343
Electrical circuit diagrams1346
Electrical diagram1348
HVAC electrical circuit diagram1374COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 23
Foreword 26
How to read the shop manual 27
Composition of shop manual 27
Revision and distribution 27
Symbols 28
General safety 29
Safety rules 29
Safety features 29
Fire extinguisher and first aid kit 29
Clothing and personal items 29
Leaving the operator seat 30
Mounting and dismounting 30
Fire prevention for fuel and oil 30
Precautions with high temperature fluids 31
Asbestos dust hazard prevention 31
Prevention of injury by work equipment 31
Unauthorized modification 31
Precautions when using ROPS 31
Precautions for attachments 32
Precautions for starting the truck 32
Precautions before operating the truck 32
Safety at the worksite 32
Fire prevention 33
Ventilation in enclosed areas 33
Preparing for operation 33
Mirrors, windows and lights 33
In operator cab (before starting the engine) 33
Seat Belts 33
Precautions while operating the truck 34
When starting the engine 34
General truck operation 34
Ensuring good visibility 34
Traveling 35
Traveling in reverse 35
Traveling on slopes 35
Operating on snow or ice 35
Avoid damage to dump body 35
Driving near high voltage cables 36
When dumping 36
When loading 36
Working on loose ground 36
Parking the truck 37
Towing 37
Working near batteries 38
Battery hazard prevention 38
Starting with jumper cables 39
Jump starting with receptacles 39
Precautions before performing service 40
Warning tag 40
Stopping the engine 40
Proper tools 40
Use of tie-off anchor during maintenance and repair 41
Tie-off anchor installation 41
Securing the dump body 42
Jack point locations 43
Precautions while performing service 44
Keep the truck clean 44
Attachments 44
Working under the truck 44
Rotating fan and belts 44
Adding fuel or oil 44
Use of lighting 44
Radiator coolant level 45
Precautions with the battery 45
Precautions with high pressure oil 45
Handling high pressure hoses 45
Precautions when performing maintenance near high temperature or high pressure 45
Waste materials 45
Tires 46
Inspection 46
Maintenance 46
Storage 47
Handling 48
Precautions for performing repairs 49
Engine shutdown procedure after AC drive system failure 49
Precautions for welding on the truck 50
Control cabinet capacitor discharge system 51
Handling electrical equipment and hydraulic components 53
Points to remember when handling electrical equipment 53
Points to remember when handling hydraulic equipment 59
Actions taken to meet exhaust gas regulations 61
About DEF 61
Precautions for diesel exhaust fluid (DEF) 62
About DEF 62
Precautions for handling DEF 62
Precautions for storing DEF 62
Precautions for disposing of DEF 63
Crystallization management 63
Precautions for cold weather operation 63
Standard tightening torques 64
Effect of special lubricants on fasteners and standard torque values 64
Suggested sources for rust preventive grease 64
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 65
SAE grade 9 capscrews 66
Class 109 capscrews and class 10 nuts 66
Standard tightening torques for fittings 67
Standard tightening torques for clamps 69
Conversion tables 70
Common conversion multipliers 70
01 Specification 75
Specification and technical data 75
Specification drawing 77
Specifications 78
Weight table 80
Fuel, coolant and lubricants 81
Suspension cylinder oil and nitrogen specifications 82
Wheel motor oil specifications 82
10 Structure and functions 85
Steering circuit 85
Steering circuit operation 86
Steering circuit components 91
Steering control unit 91
High pressure filter 91
Steering accumulators 91
Bleeddown manifold 92
Steering accumulator bleeddown solenoid 92
Quick disconnect ports 92
Flow amplifier 92
Steering/brake pump operation 93
High altitude operation 93
Neutral position 94
Full pump volume 95
Half pump volume 95
Flow amplifier operation 96
No steer 96
Steering left 98
Steering right 100
No steer, external shock load 102
Hoist circuit 105
Hoist circuit operation 106
Hoist circuit components 106
Hydraulic tank 106
Hoist pump 106
High pressure filters 106
Hoist valve 109
Inlet sections 109
Tank ports (front) spool section 109
Work ports (rear) spool section 110
Hoist pilot valve 110
Hoist limit solenoid 111
Pilot operated check valve 111
Overcenter manifold 111
Hoist pilot valve operation 112
Float position with body down 112
Power up operation 114
Hold operation 116
Power down operation 118
Float operation with body up 120
Brake circuits 123
General information 125
Service brake circuit operation 128
Secondary braking and auto apply 129
Parking brake circuit operation 130
Normal operation (key start switch ON, engine on) 130
Wheel brake lock circuit operation 131
Brake warning circuit operation 131
Electrical system, 24 volt 133
Battery supply system 135
Batteries 135
24VDC auxiliary battery receptacles 135
Isolation box 136
Ground level shutdown switch 136
Battery disconnect switches 136
Propel lockout lever 136
System busy light 136
LED lights 136
Engine starting system with prelube 137
Prelube operation 137
Cranking operation 138
Auxiliary control cabinet components 139
VEC blocks 140
24VDC to 12VDC converter 140
Circuit breakers 140
Engine service light timer 140
Ground terminals 140
24VDC power terminals 140
Relays 141
Body-up switch 142
Hoist limit switch 143
Heating/air conditioning (HVAC) system 145
Basic air conditioning system operation 147
HVAC components 149
Control panel 149
Water valve 149
Expansion valve 149
Actuators 149
Blower 149
Heater core 149
Evaporator core 149
Cab air temperature sensor 149
ECU module 149
Air filters 151
Compressor (refrigerant pump) 151
Compressor clutch 151
Trinary™ switch 152
Receiver-drier 152
Condenser 152
Accumulator 152
Automatic lubrication (auto lube) system 155
General information 157
System operation 158
Engine emissions aftertreatment system 161
About emissions aftertreatment 164
DEF injection system 164
DEF heating system 164
Sensors 164
Exhaust system cleaning 165
Propel lockout precaution 165
Inducement strategy 165
20 Standard value table 167
Standard value table 167
Standard value table for truck 169
30 Testing and adjusting 175
Steering, hoist, brake cooling and auxiliary hydraulic systems 175
Hydraulic system bleeddown procedure 177
Hydraulic system vacuum procedure 179
General information on system checkout 180
Hydraulic system checkout procedures 180
Required equipment 180
Preliminary steps 181
Hydraulic system flushing procedure 181
Flow amplifier adjustment 185
Steering pump unloader valve adjustment 186
Auxiliary accumulator pressure verification 186
System diagnostics 187
Hoist pilot relief valve adjustment 189
Hoist counterbalance valve adjustment 190
Final steps 191
Oil cleanliness check 191
Hydraulic system checkout data sheet 192
Toe-in adjustment 195
Hoist cylinder leakage test 196
Steering cylinder leakage test 196
Brake system 199
General information on system checkout 201
Brake system checkout procedures 201
Required equipment 201
Bleeddown procedure 201
Preliminary steps 204
Service brake checkout (front and rear) 205
Brake lock system checkout 206
Low brake pressure and auto apply checkout 206
Service brake checkout (left and right) 208
Parking brake checkout 209
Parking brake control logic checkout 209
Brake lock control logic checkout 211
Brake system checkout data sheet 214
Brake piston leakage test 223
Brake seal pressure test 223
Oil separator seal pressure test 223
Method 1 223
Method 2 224
Wet disc brake bleeding procedure 224
Parking brake bleeding procedure 225
Service brake disc wear inspection 226
Parking brake disc wear inspection 227
Accumulators and suspensions 229
Accumulator charging and storage 231
Temperature during precharge 231
Bladder accumulator charging procedure 232
Precharge maintenance 234
Bladder accumulator storage procedure 234
Bladder storage 234
Installing a bladder accumulator from storage 235
Bladder accumulator leak testing 235
Piston accumulator charging procedure 236
Piston accumulator storage 239
Piston accumulator leak testing 240
Checking for improper suspension charge on operating trucks 241
Suspension oil change recommendations 242
Suspension oiling and charging procedures 243
Required equipment 243
Installing the charging kit 244
Removing the charging kit 244
Support blocks for oiling and charging dimensions 245
Front suspensions 248
TOP FILL METHOD 249
PRESSURE FILL METHOD 249
Rear suspensions 251
TOP FILL METHOD 253
PRESSURE FILL METHOD 253
Suspension pressure test 256
Electrical systems 259
General information on system checkout 261
Truck shutdown procedure 262
AC drive system 263
Drive system control group components 263
Required software and tools 263
Electrical system checkout procedures 264
Visual inspection 264
Resistance checks 264
Voltage checks 265
Truck function checks 267
Interface module (IM) checks 268
KOMTRAX Plus II checks 268
Payload meter (PLM) checks 268
Drive system checks 269
Engine delayed shutdown Smart Timer check 269
Body hoist limit switch check 269
Electrical checkout sheet 270
Interface module 2 (IM2) 275
Required tools 277
Programming the IM2 277
Updating the software 277
Configuring the IM2 278
Viewing IM2 real-time data 278
Interface module checkout procedures 279
Checking for IM fault codes 279
Checking digital inputs to the IM 279
Checking analog inputs to the IM 282
Checking serial communication to the IM 282
Checking outputs from the IM 283
IM checkout sheet 284
Payload meter IV 289
Payload meter IV software and tools 291
Payload meter IV system configuration 291
Connecting to the payload meter IV web server 291
Configuring a static IP address 291
Payload meter IV software installation 293
Inclinometer calibration and clean truck tare 294
Payload meter IV checkout procedure 294
PLM IV system checkout data sheet 300
Downloading PLM IV data and possible errors 301
KOMTRAX Plus II 305
Required software and tools 307
Ethernet connection to KOMTRAX Plus II controller 307
KOMTRAX Plus II configuration 309
GPS connection test 311
Iridium satellite system opening 313
Data download over ethernet connection for KOMTRAX Plus II initialization 316
Komatsu wireless bridge (KWB) 319
General information 321
Required software and tools 321
Configuring the Bullet wireless radio 322
Installing the Bullet wireless radio 325
Configuring the NanoStation access point 326
Testing the connection 329
Changing a service computer’s IP address 330
Cab air conditioning 333
General information 335
Service tools and equipment 336
Recovery/recycle station 336
Leak detector 336
Manifold gauge set 337
Service valves 338
Vacuum pump 338
Detecting leaks 339
System performance test 340
Checking system oil 341
System flushing 342
Installing the manifold gauge set 343
Purging air from the service hoses 344
Recovering and recycling refrigerant 345
Draining oil from previous recovery cycle 346
Recovery cycle 346
Recycling procedure 346
Evacuating the air conditioning system 347
Charging the air conditioning system 348
Automatic lubrication (auto lube) system 351
Priming the system 353
Checkout procedure 355
Adjusting the lubrication cycle timing 356
Trucks with Interface Module 1 356
Trucks with Interface Module 2 356
KomVision 359
Requirements 361
Initial setup 361
Checkout data sheet 368
Calibration sheets 373
Layout and assemblage 373
Unfolding a calibration sheet 376
Folding a calibration sheet 377
Placement of calibration sheets 378
Camera calibration procedures 380
Automatic 6 camera calibration 380
Manual 6 camera calibration 384
1 camera calibration 387
Radar setting procedure 390
Tire monitoring system 395
Tire monitoring system software and tools 397
Tire monitoring system configuration 397
Connecting to the tire monitoring system web server 397
Configuring a static IP address 397
Tire monitoring system software installation 399
Tire monitoring system checkout procedure 400
Field Troubleshooting 400
Ethernet troubleshooting 400
Tire monitoring system configuration 401
CAN RPC Troubleshooting 401
Resetting the tire monitoring system 401
Tire monitoring system checkout data sheet 402
40 Troubleshooting 405
Fuse, diode and relay locations 405
Vehicle Electrical Center (VEC-89) 407
Vehicle Electrical Center (VEC-90) 409
Vehicle Electrical Center (VEC-91) 411
Vehicle Electrical Center (VEC-92) 413
Rear Terminal Mini-fuse and Relay (RTMR3) 414
Rear Terminal Mini-fuse and Relay (RTMR4) 415
Circuit breakers 416
Troubleshooting by fault code, Part 1 419
Fault Code A001 422
Fault Code A002 423
Fault Code A003 424
Fault Code A004 425
Fault Code A005 426
Fault Code A006 427
Fault Code A007 428
Fault Code A008 429
Fault Code A009 430
Related circuit diagram 430
Fault Code A010 431
Related circuit diagram 431
Fault Code A011 432
Fault Code A013 433
Fault Code A014 434
Fault Code A016 435
Fault Code A017 436
Fault Code A018 437
Fault Code A019 438
Fault Code A022 439
Fault Code A100 440
Related circuit diagram 440
Fault Code A101 441
Fault Code A103 442
Fault Code A104 443
Fault Code A105 444
Fault Code A109 445
Fault Code A111 446
Fault Code A115 447
Fault Code A117 448
Fault Code A118 449
Fault Code A123 450
Fault Code A124 451
Fault Code A125 452
Fault Code A126 453
Fault Code A127 454
Fault Code A128 455
Fault Code A139 456
Troubleshooting by fault code, Part 2 459
Fault Code A145 462
Fault Code A146 463
Fault Code A152 464
Fault Code A153 465
Fault Code A154 466
Fault Code A155 467
Fault Code A158 468
Fault Code A166 469
Fault Code A167 470
Fault Code A168 471
Fault Code A169 472
Fault Code A170 473
Fault Code A171 474
Fault Code A172 475
Fault Code A173 476
Fault Code A184 477
Fault Code A190 478
Fault Code A193 479
Fault Code A194 480
Fault Code A195 481
Fault Code A196 482
Fault Code A197 483
Fault Code A198 484
Fault Code A199 485
Fault Code A200 486
Fault Code A201 487
Fault Code A202 488
Fault Code A203 489
Fault Code A204 490
Fault Code A205 491
Fault Code A206 492
Fault Code A207 493
Fault Code A213 494
Fault Code A214 495
Fault Code A215 496
Fault Code A216 497
Fault Code A223 498
Fault Code A230 499
Fault Code A231 500
Fault Code A233 501
Fault Code A235 502
Fault Code A236 503
Fault Code A237 504
Fault Code A238 505
Fault Code A239 507
Related circuit diagram 508
Fault Code A240 509
Fault Code A242 510
Fault Code A243 511
Fault Code A244 512
Fault Code A245 513
Fault Code A246 514
Troubleshooting by fault code, Part 3 517
Fault Code A247 519
Fault Code A248 520
Fault Code A249 521
Fault Code A250 522
Fault Code A251 523
Fault Code A252 524
Fault Code A253 525
Fault Code A256 526
Fault Code A257 527
Fault Code A258 528
Fault Code A260 529
Fault Code A261 530
Fault Code A262 531
Fault Code A264 532
Fault Code A265 533
Fault Code A266 534
Fault Code A267 535
Fault Code A268 536
Fault Code A270 537
Fault Code A271 538
Related circuit diagram 539
Fault Code A272 540
Fault Code A273 541
Fault Code A274 542
Fault Code A275 543
Fault Code A277 544
Fault Code A278 545
Fault Code A279 546
Fault Code A280 547
Fault Code A281 548
Fault Code A282 549
Fault Code A283 550
Fault Code A284 551
Fault Code A285 552
Fault Code A286 553
Fault Code A292 554
Troubleshooting by fault code, Part 4 557
Fault Code A303 560
Fault Code A304 561
Fault Code A305 562
Fault Code A307 563
Fault Code A309 564
Fault Code A310 565
Fault Code A311 566
Fault Code A312 567
Fault Code A313 568
Fault Code A315 569
Fault Code A316 570
Fault Code A317 571
Fault Code A318 572
Fault Code A328 573
Fault Code A332 574
Fault Code A333 575
Fault Code A334 576
Fault Code A335 577
Fault Code A337 578
Fault Code A338 579
Fault Code A339 580
Fault Code A340 581
Fault Code A341 582
Fault Code A342 583
Fault Code A343 584
Fault Code A344 585
Fault Code A345 586
Fault Code A346 587
Fault Code A347 588
Fault Code A348 589
Fault Code A349 590
Fault Code A350 591
Fault Code A351 592
Fault Code A352 593
Fault Code A353 594
Fault Code A354 595
Fault Code A355 596
Fault Code A356 597
Fault Code A357 598
Fault Code A358 599
Fault Code A359 600
Fault Code A360 601
Fault Code A361 602
Fault Code A362 603
Fault Code A363 604
Fault Code A364 605
Fault Code A365 606
Fault Code A366 607
Troubleshooting by fault code, Part 5 609
Fault Code A400 612
Fault Code A401 613
Fault Code A402 614
Fault Code A403 615
Fault Code A404 616
Fault Code A405 617
Fault Code A406 618
Fault Code A407 619
Fault Code A408 620
Fault Code A409 621
Fault Code A410 622
Fault Code A411 623
Fault Code A412 624
Fault Code A413 625
Fault Code A414 626
Fault Code A415 627
Fault Code A416 628
Fault Code A417 629
Fault Code A418 630
Fault Code A419 631
Fault Code A420 632
Fault Code A421 633
Fault Code A422 634
Fault Code A423 635
Fault Code A424 636
Fault Code A425 637
Fault Code A426 638
Fault Code A427 639
Fault Code A428 640
Fault Code A429 641
Fault Code A430 642
Fault Code A431 643
Fault Code A432 644
Fault Code A433 645
Fault Code A434 646
Fault Code A435 647
Fault Code A436 648
Fault Code A437 649
Fault Code A438 650
Fault Code A439 651
Fault Code A440 652
Fault Code A441 653
Fault Code A442 654
Fault Code A443 655
Fault Code A444 656
Fault Code A445 657
Fault Code A446 658
Fault Code A447 659
Aftertreatment system fault codes 661
Fault Code CA256 665
Fault Code CA1677 667
Fault Code CA1678 669
Fault Code CA1682 672
Fault Code CA1683 679
Fault Code CA1684 681
Fault Code CA1685 683
Fault Code CA1686 685
Fault Code CA1712 687
Fault Code CA1713 689
Fault Code CA1714 691
Fault Code CA1715 692
Fault Code CA1887 694
Fault Code CA2771 695
Fault Code CA3142 699
Fault Code CA3143 701
Fault Code CA3146 703
Fault Code CA3147 705
Fault Code CA3232 707
Fault Code CA3497 710
Fault Code CA3498 711
Fault Code CA3547 712
Fault Code CA3558 713
Fault Code CA3559 715
Fault Code CA3562 717
Fault Code CA3563 719
Fault Code CA3567 721
Fault Code CA3571 723
Fault Code CA3572 725
Fault Code CA3573 728
Fault Code CA3574 730
Fault Code CA3575 732
Fault Code CA3712 734
Fault Code CA3713 735
Fault Code CA3714 738
Fault Code CA3867 739
Fault Code CA3868 741
Fault Code CA3878 744
Fault Code CA3988 745
Fault Code CA3995 749
Fault Code CA4113 751
Fault Code CA4114 753
Fault Code CA4119 755
Fault Code CA4121 757
Fault Code CA4152 759
Fault Code CA4164 763
Fault Code CA4165 765
Fault Code CA4166 768
Fault Code CA4168 770
Fault Code CA4169 772
Fault Code CA4174 774
Fault Code CA4175 776
Fault Code CA4233 779
Fault Code CA4234 780
Fault Code CA4243 781
Fault Code CA4277 782
Fault Code CA4457 784
Fault Code CA4458 786
Fault Code CA4459 789
Fault Code CA4461 791
Fault Code CA4462 793
Fault Code CA4464 795
Fault Code CA4465 797
Fault Code CA4466 800
Fault Code CA4467 807
Fault Code CA4474 809
Fault Code CA4475 811
Fault Code CA4572 814
Fault Code CA4677 818
Fault Code CA4679 822
Fault Code CA4682 823
Fault Code CA4731 824
Fault Code CA4732 825
Fault Code CA4736 826
Fault Code CA4737 827
Fault Code CA4738 828
Fault Code CA4739 829
Fault Code CA4745 830
Fault Code CA4768 831
Fault Code CA4769 833
Fault Code CA4842 835
Fault Code CA4863 836
Fault Code CA4947 837
Fault Code CA5115 838
Fault Code CA5116 841
Fault Code CA5117 844
Fault Code CA5247 847
Fault Code CA5653 849
Fault Code CA5654 852
Fault Code CA5725 854
Fault Code CA5727 859
Fault Code CA5728 862
Fault Code CA5729 865
Fault Code CA5748 867
Fault Code CA5749 869
Fault Code CA5751 871
Fault Code CA5753 873
Fault Code CA5755 876
Fault Code CA5756 881
Fault Code CA5758 883
Fault Code CA5768 885
Fault Code CA5769 887
Fault Code CA5771 890
Fault Code CA5772 892
Fault Code CA5773 895
Fault Code CA5774 898
Fault Code CA5775 900
Fault Code CA5776 905
Fault Code CA5778 907
Fault Code CA5779 909
Fault Code CA5887 911
Fault Code CA5888 912
Fault Code CA5889 913
Fault Code CA5891 914
Fault Code CA5892 915
Fault Code CA5893 916
Fault Code CA6692 917
Fault Code CA6693 919
Fault Code CA6694 921
Fault Code CA6695 923
Fault Code CA6696 925
Fault Code CA6697 927
Fault Code CA6855 929
Fault Code CA6856 932
Steering system 935
Steering circuit troubleshooting chart 937
Steering circuit troubleshooting guidelines 939
Basic hydraulic system checks 940
System leakage check 941
Steering pump troubleshooting guide 943
Pump pressure control checks 946
Pump fails to unload 947
Pump fails to develop pressure 947
Pump slow in developing pressure 948
Pump control valve inspection and troubleshooting 949
Pump case drain check 951
Setting pump pressure controls 951
KomVision 955
KomVision fault codes 957
Automatic lubrication (auto lube) system 967
Autolube troubleshooting chart 969
Heating/air conditioning (HVAC) system 973
Control panel configurations 975
Diagnostics mode 976
Error codes 976
Advanced diagnostics 976
Firmware version 977
Additional HVAC troubleshooting chart 977
Voltage levels 979
Electronic fan clutch 981
Electronic fan clutch troubleshooting 983
Electronic fan clutch fault codes 985
50 Disassembly and assembly 987
Service tools 987
Special tool group 989
Additional service tools 990
KomVision calibration tools 991
Locally made tools 991
Wheels, spindles and rear axle 993
General precautions for tires and rims 995
Wheel stud maintenance 996
Rear outer wheel stud installation 997
Removal and installation of front wheel 998
Removal 998
Installation 999
Removal and installation of rear wheel1000
Removal1000
Installation1001
Rim components1003
Smart Rim Component Layout1003
Rim and tire service1004
Lubricants1004
Tire inflation1004
Lock ring retainer installation1004
Removing the lock ring1005
Installing the lock ring1006
Removing the tire from the front rim (5-piece rim)1007
Removing the tire from the rear outer dual rim (7-piece Smart rim)1010
Removing the tire from the rear inner dual rim (5-piece rim)1012
Preparation before assembly1013
Installing the tire on the front rim (5-piece rim)1014
Installing the tire on the rear inner dual rim (5-piece rim)1016
Installing the tire on the rear outer dual rim (7-piece Smart rim)1017
Removal and installation of front wheel hub and spindle1018
Removal1018
Spindle removal (off the truck)1024
Installation1026
Disassembly and assembly of front wheel hub and spindle1027
Cross Section View1027
Disassembly1028
Cleaning and inspection1035
Assembly1036
Wheel bearing adjustment1038
Seal assembly gap adjustment1039
Brake seal installation1040
Oil separation seal installation1041
Brake installation1042
Speed sensor installation and adjustment1046
Floating ring seal assembly and installation1048
Removal and installation of rear axle1057
Removal1057
Cleaning and inspection1059
Installation1059
Removal and installation of anti-sway bar1060
Removal1060
Installation1062
Removal and installation of pivot pin1063
Removal1063
Installation1064
Removal and installation of pivot bearing1065
Replacement criteria1065
Removal1067
Inspection1067
Installation1067
Removal and installation of pivot eye1068
Removal1068
Inspection1068
Installation1068
Removal of wheel motor1069
Preparation1069
Installation of wheel motor1071
Cleaning and inspection1071
Installation1072
Removal and installation of rear brake assembly1075
Brake system1077
Removal and installation of brake valve1079
Removal1079
Installation1080
Disassembly and assembly of brake valve/pedal assembly1081
Disassembly1081
Assembly1082
Removal and installation of dual relay valve1085
Removal1085
Installation1086
Removal and installation of brake manifold1087
Removal1087
Installation1087
Disassembly and assembly of brake manifold1088
Disassembly1088
Assembly1088
Removal and installation of piston brake accumulator1089
Removal1089
Installation1091
Disassembly and assembly of piston brake accumulator1093
Disassembly1093
Cleaning and inspection1095
Piston seal replacement1095
Assembly1096
Disassembly and assembly of front wheel brake1097
Disassembly1097
Cleaning and inspection1100
Assembly1101
Disassembly and assembly of rear wheel brake1103
Disassembly1103
Cleaning and inspection1107
Assembly1108
Brake floating ring seal assembly and installation1112
Rear hub floating ring seal assembly and installation1121
Removal and installation of parking brake1127
Removal1127
Installation1129
Disassembly and assembly of parking brake1130
Disassemble and reassemble the brake assembly on a clean, dry work surface The work surface should be wooden If the work surface is metal or concrete, use padding to prevent damage to machined surfaces Handle all parts carefully to avoid damage to1130
Disassembly1130
Cleaning and inspection1132
Cleaning and inspecting new discs1134
Assembly1135
Steering system1137
Removal and installation of steering control unit1139
Removal1139
Installation1141
Disassembly and assembly of steering control unit1142
Disassembly1142
Assembly1144
Removal and installation of steering column1147
Removal1147
Installation1148
Removal and installation of steering wheel1149
Removal1149
Installation1149
Removal and installation of bleeddown manifold1150
Removal1150
Installation1151
Removal and installation of flow amplifier1152
Removal1152
Installation1152
Removal and installation of steering cylinders and tie rod1153
Removal1153
Installation1153
Disassembly and assembly of steering cylinders1155
Disassembly1155
Cleaning and inspection1157
Assembly1157
Removal and installation of steering/brake pump1158
Removal1158
Installation1160
Removal and installation of piston steering accumulator1161
Removal1161
Installation1163
Disassembly and assembly of piston steering accumulator1165
Disassembly1165
Cleaning and inspection1167
Piston seal replacement1167
Assembly1168
Suspensions1171
General information1173
Removal and installation of front suspension1173
Preparation1173
Removal1173
Cleaning and Inspection1175
Installation1176
Disassembly and assembly of front suspension1181
Disassembly1181
Cleaning and inspection1184
Assembly1184
Removal and installation of rear suspension1186
Removal1186
Installation1189
Disassembly and assembly of rear suspension1192
Disassembly1192
Cleaning and inspection1194
Assembly1195
Hoist circuit1197
Removal and installation of hoist pump1199
Removal1199
Installation1203
Disassembly and assembly of hoist pump1204
Disassembly1204
Inspection1209
Assembly1210
Removal and installation of hoist valve1213
Removal1213
Installation1215
Disassembly and assembly of hoist valve1215
O-ring replacement1215
Disassembly of inlet section1217
Assembly of inlet section1218
Disassembly of rear spool section1219
Assembly of rear spool section1221
Disassembly of front spool section1222
Assembly of front spool section1223
Overcenter manifold service1223
Removal and installation of hoist pilot valve1224
Removal1224
Installation1224
Disassembly and assembly of hoist pilot valve1226
Disassembly1226
Cleaning and inspection1227
Assembly1227
Removal and installation of hoist cylinders1228
Removal1228
Installation1230
Disassembly and assembly of hoist cylinders1231
Disassembly1231
Cleaning and inspection1235
Installation of the quill1236
Assembly1238
Body and structures1243
Removal and installation of dump body1245
Removal1245
Inspection1246
Installation1247
Removal and installation of body pads1248
Removal1248
Installation1248
Body pad shimming procedure1249
Removal and installation of diagonal ladder/ hood and grille assembly1250
Removal1250
Installation1250
Removal and installation of RH deck1252
Removal1252
Installation1252
Removal and installation of LH deck1254
Removal1254
Installation1254
Removal and installation of fuel tank (with DEF tank)1256
Removal1256
Cleaning and inspection1256
Installation1258
Removal and installation of fuel gauge sender1258
Removal1258
Installation1258
Removal and installation of hydraulic tank1259
Removal1259
Installation1260
Removal and installation of hydraulic tank strainers1261
Removal1261
Cleaning and inspection1262
Installation1262
Operator cab1265
Removal and installation of operator cab1267
Removal1267
Installation1270
Removal and installation of cab door1270
Removal1270
Installation1271
Disassembly and assembly of cab door1272
Removing the window regulator1272
Installing the window regulator1273
Removing the door glass1274
Installing the door glass1275
Replacing the inner door seal1276
Replacing the outer door seal1276
Removing the interior door handle and door latch (earlier models)1277
Installation and removal of interior door handle and door latch (later models)1280
Adjustment of cab door1282
Door jamb bolt adjustment1282
Exterior door handle release button adjustment1284
Removal and installation of side window glass1285
Recommended tools and supplies1285
Removal1285
Installation1286
Removal and installation of windshield and rear window glass1287
Removal1287
Installation1287
Removal and installation of windshield wiper components1288
Removing the windshield wiper motor1288
Installing the windshield wiper motor1288
Removing the windshield wiper arm and linkage1289
Installing the windshield wiper arm and linkage1290
Removal and installation of cab seats1290
Removal1290
Servicing the seat1291
Installation1291
Removal and installation of seat belts1292
Removal1292
Installation1293
Power module1295
Removal and installation of power module1297
General1297
Removal1298
Installation1307
Exhaust tube installation1310
Exhaust blanket installation1310
Removal and installation of alternator1311
Removal1311
Installation1314
Removal and installation of radiator1325
Removal1325
Installation1330
Repairing the radiator1331
Internal inspection1331
External cleaning1331
Disassembly1331
Cleaning and inspection1332
Assembly1333
Pressure testing1334
Removal and installation of engine1334
Removal1334
Service1334
Installation1335
Removal and installation of electronic fan clutch1336
Removal1336
Installation1337
Removal and installation of electronic fan clutch speed sensor1337
Removal1337
Installation1337
90 Diagrams and drawings1339
Hydraulic circuit diagrams1339
Steering, hoist and brake cooling hydraulic circuit diagram1341
Brake hydraulic circuit diagram1342
Auxiliary system hydraulic circuit schematic1343
Electrical circuit diagrams1346
Electrical diagram1348
HVAC electrical circuit diagram1374

TABLE OF CONTENTS:

Komatsu 980E-5SU DUMP TRUCK Shop Manual CEBM035300 – PDF DOWNLOAD

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 23
Foreword 26
How to read the shop manual 27
Composition of shop manual 27
Revision and distribution 27
Symbols 28
General safety 29
Safety rules 29
Safety features 29
Fire extinguisher and first aid kit 29
Clothing and personal items 29
Leaving the operator seat 30
Mounting and dismounting 30
Fire prevention for fuel and oil 30
Precautions with high temperature fluids 31
Asbestos dust hazard prevention 31
Prevention of injury by work equipment 31
Unauthorized modification 31
Precautions when using ROPS 31
Precautions for attachments 32
Precautions for starting the truck 32
Precautions before operating the truck 32
Safety at the worksite 32
Fire prevention 33
Ventilation in enclosed areas 33
Preparing for operation 33
Mirrors, windows and lights 33
In operator cab (before starting the engine) 33
Seat Belts 33
Precautions while operating the truck 34
When starting the engine 34
General truck operation 34
Ensuring good visibility 34
Traveling 35
Traveling in reverse 35
Traveling on slopes 35
Operating on snow or ice 35
Avoid damage to dump body 35
Driving near high voltage cables 36
When dumping 36
When loading 36
Working on loose ground 36
Parking the truck 37
Towing 37
Working near batteries 38
Battery hazard prevention 38
Starting with jumper cables 39
Jump starting with receptacles 39
Precautions before performing service 40
Warning tag 40
Stopping the engine 40
Proper tools 40
Use of tie-off anchor during maintenance and repair 41
Tie-off anchor installation 41
Securing the dump body 42
Jack point locations 43
Precautions while performing service 44
Keep the truck clean 44
Attachments 44
Working under the truck 44
Rotating fan and belts 44
Adding fuel or oil 44
Use of lighting 44
Radiator coolant level 45
Precautions with the battery 45
Precautions with high pressure oil 45
Handling high pressure hoses 45
Precautions when performing maintenance near high temperature or high pressure 45
Waste materials 45
Tires 46
Inspection 46
Maintenance 46
Storage 47
Handling 48
Precautions for performing repairs 49
Engine shutdown procedure after AC drive system failure 49
Precautions for welding on the truck 50
Control cabinet capacitor discharge system 51
Handling electrical equipment and hydraulic components 53
Points to remember when handling electrical equipment 53
Points to remember when handling hydraulic equipment 59
Actions taken to meet exhaust gas regulations 61
About DEF 61
Precautions for diesel exhaust fluid (DEF) 62
About DEF 62
Precautions for handling DEF 62
Precautions for storing DEF 62
Precautions for disposing of DEF 63
Crystallization management 63
Precautions for cold weather operation 63
Standard tightening torques 64
Effect of special lubricants on fasteners and standard torque values 64
Suggested sources for rust preventive grease 64
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 65
SAE grade 9 capscrews 66
Class 109 capscrews and class 10 nuts 66
Standard tightening torques for fittings 67
Standard tightening torques for clamps 69
Conversion tables 70
Common conversion multipliers 70
01 Specification 75
Specification and technical data 75
Specification drawing 77
Specifications 78
Weight table 80
Fuel, coolant and lubricants 81
Suspension cylinder oil and nitrogen specifications 82
Wheel motor oil specifications 82
10 Structure and functions 85
Steering circuit 85
Steering circuit operation 86
Steering circuit components 91
Steering control unit 91
High pressure filter 91
Steering accumulators 91
Bleeddown manifold 92
Steering accumulator bleeddown solenoid 92
Quick disconnect ports 92
Flow amplifier 92
Steering/brake pump operation 93
High altitude operation 93
Neutral position 94
Full pump volume 95
Half pump volume 95
Flow amplifier operation 96
No steer 96
Steering left 98
Steering right 100
No steer, external shock load 102
Hoist circuit 105
Hoist circuit operation 106
Hoist circuit components 106
Hydraulic tank 106
Hoist pump 106
High pressure filters 106
Hoist valve 109
Inlet sections 109
Tank ports (front) spool section 109
Work ports (rear) spool section 110
Hoist pilot valve 110
Hoist limit solenoid 111
Pilot operated check valve 111
Overcenter manifold 111
Hoist pilot valve operation 112
Float position with body down 112
Power up operation 114
Hold operation 116
Power down operation 118
Float operation with body up 120
Brake circuits 123
General information 125
Service brake circuit operation 128
Secondary braking and auto apply 129
Parking brake circuit operation 130
Normal operation (key start switch ON, engine on) 130
Wheel brake lock circuit operation 131
Brake warning circuit operation 131
Electrical system, 24 volt 133
Battery supply system 135
Batteries 135
24VDC auxiliary battery receptacles 135
Isolation box 136
Ground level shutdown switch 136
Battery disconnect switches 136
Propel lockout lever 136
System busy light 136
LED lights 136
Engine starting system with prelube 137
Prelube operation 137
Cranking operation 138
Auxiliary control cabinet components 139
VEC blocks 140
24VDC to 12VDC converter 140
Circuit breakers 140
Engine service light timer 140
Ground terminals 140
24VDC power terminals 140
Relays 141
Body-up switch 142
Hoist limit switch 143
Heating/air conditioning (HVAC) system 145
Basic air conditioning system operation 147
HVAC components 149
Control panel 149
Water valve 149
Expansion valve 149
Actuators 149
Blower 149
Heater core 149
Evaporator core 149
Cab air temperature sensor 149
ECU module 149
Air filters 151
Compressor (refrigerant pump) 151
Compressor clutch 151
Trinary™ switch 152
Receiver-drier 152
Condenser 152
Accumulator 152
Automatic lubrication (auto lube) system 155
General information 157
System operation 158
Engine emissions aftertreatment system 161
About emissions aftertreatment 164
DEF injection system 164
DEF heating system 164
Sensors 164
Exhaust system cleaning 165
Propel lockout precaution 165
Inducement strategy 165
20 Standard value table 167
Standard value table 167
Standard value table for truck 169
30 Testing and adjusting 175
Steering, hoist, brake cooling and auxiliary hydraulic systems 175
Hydraulic system bleeddown procedure 177
Hydraulic system vacuum procedure 179
General information on system checkout 180
Hydraulic system checkout procedures 180
Required equipment 180
Preliminary steps 181
Hydraulic system flushing procedure 181
Flow amplifier adjustment 185
Steering pump unloader valve adjustment 186
Auxiliary accumulator pressure verification 186
System diagnostics 187
Hoist pilot relief valve adjustment 189
Hoist counterbalance valve adjustment 190
Final steps 191
Oil cleanliness check 191
Hydraulic system checkout data sheet 192
Toe-in adjustment 195
Hoist cylinder leakage test 196
Steering cylinder leakage test 196
Brake system 199
General information on system checkout 201
Brake system checkout procedures 201
Required equipment 201
Bleeddown procedure 201
Preliminary steps 204
Service brake checkout (front and rear) 205
Brake lock system checkout 206
Low brake pressure and auto apply checkout 206
Service brake checkout (left and right) 208
Parking brake checkout 209
Parking brake control logic checkout 209
Brake lock control logic checkout 211
Brake system checkout data sheet 214
Brake piston leakage test 223
Brake seal pressure test 223
Oil separator seal pressure test 223
Method 1 223
Method 2 224
Wet disc brake bleeding procedure 224
Parking brake bleeding procedure 225
Service brake disc wear inspection 226
Parking brake disc wear inspection 227
Accumulators and suspensions 229
Accumulator charging and storage 231
Temperature during precharge 231
Bladder accumulator charging procedure 232
Precharge maintenance 234
Bladder accumulator storage procedure 234
Bladder storage 234
Installing a bladder accumulator from storage 235
Bladder accumulator leak testing 235
Piston accumulator charging procedure 236
Piston accumulator storage 239
Piston accumulator leak testing 240
Checking for improper suspension charge on operating trucks 241
Suspension oil change recommendations 242
Suspension oiling and charging procedures 243
Required equipment 243
Installing the charging kit 244
Removing the charging kit 244
Support blocks for oiling and charging dimensions 245
Front suspensions 248
TOP FILL METHOD 249
PRESSURE FILL METHOD 249
Rear suspensions 251
TOP FILL METHOD 253
PRESSURE FILL METHOD 253
Suspension pressure test 256
Electrical systems 259
General information on system checkout 261
Truck shutdown procedure 262
AC drive system 263
Drive system control group components 263
Required software and tools 263
Electrical system checkout procedures 264
Visual inspection 264
Resistance checks 264
Voltage checks 265
Truck function checks 267
Interface module (IM) checks 268
KOMTRAX Plus II checks 268
Payload meter (PLM) checks 268
Drive system checks 269
Engine delayed shutdown Smart Timer check 269
Body hoist limit switch check 269
Electrical checkout sheet 270
Interface module 2 (IM2) 275
Required tools 277
Programming the IM2 277
Updating the software 277
Configuring the IM2 278
Viewing IM2 real-time data 278
Interface module checkout procedures 279
Checking for IM fault codes 279
Checking digital inputs to the IM 279
Checking analog inputs to the IM 282
Checking serial communication to the IM 282
Checking outputs from the IM 283
IM checkout sheet 284
Payload meter IV 289
Payload meter IV software and tools 291
Payload meter IV system configuration 291
Connecting to the payload meter IV web server 291
Configuring a static IP address 291
Payload meter IV software installation 293
Inclinometer calibration and clean truck tare 294
Payload meter IV checkout procedure 294
PLM IV system checkout data sheet 300
Downloading PLM IV data and possible errors 301
KOMTRAX Plus II 305
Required software and tools 307
Ethernet connection to KOMTRAX Plus II controller 307
KOMTRAX Plus II configuration 309
GPS connection test 311
Iridium satellite system opening 313
Data download over ethernet connection for KOMTRAX Plus II initialization 316
Komatsu wireless bridge (KWB) 319
General information 321
Required software and tools 321
Configuring the Bullet wireless radio 322
Installing the Bullet wireless radio 325
Configuring the NanoStation access point 326
Testing the connection 329
Changing a service computer’s IP address 330
Cab air conditioning 333
General information 335
Service tools and equipment 336
Recovery/recycle station 336
Leak detector 336
Manifold gauge set 337
Service valves 338
Vacuum pump 338
Detecting leaks 339
System performance test 340
Checking system oil 341
System flushing 342
Installing the manifold gauge set 343
Purging air from the service hoses 344
Recovering and recycling refrigerant 345
Draining oil from previous recovery cycle 346
Recovery cycle 346
Recycling procedure 346
Evacuating the air conditioning system 347
Charging the air conditioning system 348
Automatic lubrication (auto lube) system 351
Priming the system 353
Checkout procedure 355
Adjusting the lubrication cycle timing 356
Trucks with Interface Module 1 356
Trucks with Interface Module 2 356
KomVision 359
Requirements 361
Initial setup 361
Checkout data sheet 368
Calibration sheets 373
Layout and assemblage 373
Unfolding a calibration sheet 376
Folding a calibration sheet 377
Placement of calibration sheets 378
Camera calibration procedures 380
Automatic 6 camera calibration 380
Manual 6 camera calibration 384
1 camera calibration 387
Radar setting procedure 390
Tire monitoring system 395
Tire monitoring system software and tools 397
Tire monitoring system configuration 397
Connecting to the tire monitoring system web server 397
Configuring a static IP address 397
Tire monitoring system software installation 399
Tire monitoring system checkout procedure 400
Field Troubleshooting 400
Ethernet troubleshooting 400
Tire monitoring system configuration 401
CAN RPC Troubleshooting 401
Resetting the tire monitoring system 401
Tire monitoring system checkout data sheet 402
40 Troubleshooting 405
Fuse, diode and relay locations 405
Vehicle Electrical Center (VEC-89) 407
Vehicle Electrical Center (VEC-90) 409
Vehicle Electrical Center (VEC-91) 411
Vehicle Electrical Center (VEC-92) 413
Rear Terminal Mini-fuse and Relay (RTMR3) 414
Rear Terminal Mini-fuse and Relay (RTMR4) 415
Circuit breakers 416
Troubleshooting by fault code, Part 1 419
Fault Code A001 422
Fault Code A002 423
Fault Code A003 424
Fault Code A004 425
Fault Code A005 426
Fault Code A006 427
Fault Code A007 428
Fault Code A008 429
Fault Code A009 430
Related circuit diagram 430
Fault Code A010 431
Related circuit diagram 431
Fault Code A011 432
Fault Code A013 433
Fault Code A014 434
Fault Code A016 435
Fault Code A017 436
Fault Code A018 437
Fault Code A019 438
Fault Code A022 439
Fault Code A100 440
Related circuit diagram 440
Fault Code A101 441
Fault Code A103 442
Fault Code A104 443
Fault Code A105 444
Fault Code A109 445
Fault Code A111 446
Fault Code A115 447
Fault Code A117 448
Fault Code A118 449
Fault Code A123 450
Fault Code A124 451
Fault Code A125 452
Fault Code A126 453
Fault Code A127 454
Fault Code A128 455
Fault Code A139 456
Troubleshooting by fault code, Part 2 459
Fault Code A145 462
Fault Code A146 463
Fault Code A152 464
Fault Code A153 465
Fault Code A154 466
Fault Code A155 467
Fault Code A158 468
Fault Code A166 469
Fault Code A167 470
Fault Code A168 471
Fault Code A169 472
Fault Code A170 473
Fault Code A171 474
Fault Code A172 475
Fault Code A173 476
Fault Code A184 477
Fault Code A190 478
Fault Code A193 479
Fault Code A194 480
Fault Code A195 481
Fault Code A196 482
Fault Code A197 483
Fault Code A198 484
Fault Code A199 485
Fault Code A200 486
Fault Code A201 487
Fault Code A202 488
Fault Code A203 489
Fault Code A204 490
Fault Code A205 491
Fault Code A206 492
Fault Code A207 493
Fault Code A213 494
Fault Code A214 495
Fault Code A215 496
Fault Code A216 497
Fault Code A223 498
Fault Code A230 499
Fault Code A231 500
Fault Code A233 501
Fault Code A235 502
Fault Code A236 503
Fault Code A237 504
Fault Code A238 505
Fault Code A239 507
Related circuit diagram 508
Fault Code A240 509
Fault Code A242 510
Fault Code A243 511
Fault Code A244 512
Fault Code A245 513
Fault Code A246 514
Troubleshooting by fault code, Part 3 517
Fault Code A247 519
Fault Code A248 520
Fault Code A249 521
Fault Code A250 522
Fault Code A251 523
Fault Code A252 524
Fault Code A253 525
Fault Code A256 526
Fault Code A257 527
Fault Code A258 528
Fault Code A260 529
Fault Code A261 530
Fault Code A262 531
Fault Code A264 532
Fault Code A265 533
Fault Code A266 534
Fault Code A267 535
Fault Code A268 536
Fault Code A270 537
Fault Code A271 538
Related circuit diagram 539
Fault Code A272 540
Fault Code A273 541
Fault Code A274 542
Fault Code A275 543
Fault Code A277 544
Fault Code A278 545
Fault Code A279 546
Fault Code A280 547
Fault Code A281 548
Fault Code A282 549
Fault Code A283 550
Fault Code A284 551
Fault Code A285 552
Fault Code A286 553
Fault Code A292 554
Troubleshooting by fault code, Part 4 557
Fault Code A303 560
Fault Code A304 561
Fault Code A305 562
Fault Code A307 563
Fault Code A309 564
Fault Code A310 565
Fault Code A311 566
Fault Code A312 567
Fault Code A313 568
Fault Code A315 569
Fault Code A316 570
Fault Code A317 571
Fault Code A318 572
Fault Code A328 573
Fault Code A332 574
Fault Code A333 575
Fault Code A334 576
Fault Code A335 577
Fault Code A337 578
Fault Code A338 579
Fault Code A339 580
Fault Code A340 581
Fault Code A341 582
Fault Code A342 583
Fault Code A343 584
Fault Code A344 585
Fault Code A345 586
Fault Code A346 587
Fault Code A347 588
Fault Code A348 589
Fault Code A349 590
Fault Code A350 591
Fault Code A351 592
Fault Code A352 593
Fault Code A353 594
Fault Code A354 595
Fault Code A355 596
Fault Code A356 597
Fault Code A357 598
Fault Code A358 599
Fault Code A359 600
Fault Code A360 601
Fault Code A361 602
Fault Code A362 603
Fault Code A363 604
Fault Code A364 605
Fault Code A365 606
Fault Code A366 607
Troubleshooting by fault code, Part 5 609
Fault Code A400 612
Fault Code A401 613
Fault Code A402 614
Fault Code A403 615
Fault Code A404 616
Fault Code A405 617
Fault Code A406 618
Fault Code A407 619
Fault Code A408 620
Fault Code A409 621
Fault Code A410 622
Fault Code A411 623
Fault Code A412 624
Fault Code A413 625
Fault Code A414 626
Fault Code A415 627
Fault Code A416 628
Fault Code A417 629
Fault Code A418 630
Fault Code A419 631
Fault Code A420 632
Fault Code A421 633
Fault Code A422 634
Fault Code A423 635
Fault Code A424 636
Fault Code A425 637
Fault Code A426 638
Fault Code A427 639
Fault Code A428 640
Fault Code A429 641
Fault Code A430 642
Fault Code A431 643
Fault Code A432 644
Fault Code A433 645
Fault Code A434 646
Fault Code A435 647
Fault Code A436 648
Fault Code A437 649
Fault Code A438 650
Fault Code A439 651
Fault Code A440 652
Fault Code A441 653
Fault Code A442 654
Fault Code A443 655
Fault Code A444 656
Fault Code A445 657
Fault Code A446 658
Fault Code A447 659
Aftertreatment system fault codes 661
Fault Code CA256 665
Fault Code CA1677 667
Fault Code CA1678 669
Fault Code CA1682 672
Fault Code CA1683 679
Fault Code CA1684 681
Fault Code CA1685 683
Fault Code CA1686 685
Fault Code CA1712 687
Fault Code CA1713 689
Fault Code CA1714 691
Fault Code CA1715 692
Fault Code CA1887 694
Fault Code CA2771 695
Fault Code CA3142 699
Fault Code CA3143 701
Fault Code CA3146 703
Fault Code CA3147 705
Fault Code CA3232 707
Fault Code CA3497 710
Fault Code CA3498 711
Fault Code CA3547 712
Fault Code CA3558 713
Fault Code CA3559 715
Fault Code CA3562 717
Fault Code CA3563 719
Fault Code CA3567 721
Fault Code CA3571 723
Fault Code CA3572 725
Fault Code CA3573 728
Fault Code CA3574 730
Fault Code CA3575 732
Fault Code CA3712 734
Fault Code CA3713 735
Fault Code CA3714 738
Fault Code CA3867 739
Fault Code CA3868 741
Fault Code CA3878 744
Fault Code CA3988 745
Fault Code CA3995 749
Fault Code CA4113 751
Fault Code CA4114 753
Fault Code CA4119 755
Fault Code CA4121 757
Fault Code CA4152 759
Fault Code CA4164 763
Fault Code CA4165 765
Fault Code CA4166 768
Fault Code CA4168 770
Fault Code CA4169 772
Fault Code CA4174 774
Fault Code CA4175 776
Fault Code CA4233 779
Fault Code CA4234 780
Fault Code CA4243 781
Fault Code CA4277 782
Fault Code CA4457 784
Fault Code CA4458 786
Fault Code CA4459 789
Fault Code CA4461 791
Fault Code CA4462 793
Fault Code CA4464 795
Fault Code CA4465 797
Fault Code CA4466 800
Fault Code CA4467 807
Fault Code CA4474 809
Fault Code CA4475 811
Fault Code CA4572 814
Fault Code CA4677 818
Fault Code CA4679 822
Fault Code CA4682 823
Fault Code CA4731 824
Fault Code CA4732 825
Fault Code CA4736 826
Fault Code CA4737 827
Fault Code CA4738 828
Fault Code CA4739 829
Fault Code CA4745 830
Fault Code CA4768 831
Fault Code CA4769 833
Fault Code CA4842 835
Fault Code CA4863 836
Fault Code CA4947 837
Fault Code CA5115 838
Fault Code CA5116 841
Fault Code CA5117 844
Fault Code CA5247 847
Fault Code CA5653 849
Fault Code CA5654 852
Fault Code CA5725 854
Fault Code CA5727 859
Fault Code CA5728 862
Fault Code CA5729 865
Fault Code CA5748 867
Fault Code CA5749 869
Fault Code CA5751 871
Fault Code CA5753 873
Fault Code CA5755 876
Fault Code CA5756 881
Fault Code CA5758 883
Fault Code CA5768 885
Fault Code CA5769 887
Fault Code CA5771 890
Fault Code CA5772 892
Fault Code CA5773 895
Fault Code CA5774 898
Fault Code CA5775 900
Fault Code CA5776 905
Fault Code CA5778 907
Fault Code CA5779 909
Fault Code CA5887 911
Fault Code CA5888 912
Fault Code CA5889 913
Fault Code CA5891 914
Fault Code CA5892 915
Fault Code CA5893 916
Fault Code CA6692 917
Fault Code CA6693 919
Fault Code CA6694 921
Fault Code CA6695 923
Fault Code CA6696 925
Fault Code CA6697 927
Fault Code CA6855 929
Fault Code CA6856 932
Steering system 935
Steering circuit troubleshooting chart 937
Steering circuit troubleshooting guidelines 939
Basic hydraulic system checks 940
System leakage check 941
Steering pump troubleshooting guide 943
Pump pressure control checks 946
Pump fails to unload 947
Pump fails to develop pressure 947
Pump slow in developing pressure 948
Pump control valve inspection and troubleshooting 949
Pump case drain check 951
Setting pump pressure controls 951
KomVision 955
KomVision fault codes 957
Automatic lubrication (auto lube) system 967
Autolube troubleshooting chart 969
Heating/air conditioning (HVAC) system 973
Control panel configurations 975
Diagnostics mode 976
Error codes 976
Advanced diagnostics 976
Firmware version 977
Additional HVAC troubleshooting chart 977
Voltage levels 979
Electronic fan clutch 981
Electronic fan clutch troubleshooting 983
Electronic fan clutch fault codes 985
50 Disassembly and assembly 987
Service tools 987
Special tool group 989
Additional service tools 990
KomVision calibration tools 991
Locally made tools 991
Wheels, spindles and rear axle 993
General precautions for tires and rims 995
Wheel stud maintenance 996
Rear outer wheel stud installation 997
Removal and installation of front wheel 998
Removal 998
Installation 999
Removal and installation of rear wheel1000
Removal1000
Installation1001
Rim components1003
Smart Rim Component Layout1003
Rim and tire service1004
Lubricants1004
Tire inflation1004
Lock ring retainer installation1004
Removing the lock ring1005
Installing the lock ring1006
Removing the tire from the front rim (5-piece rim)1007
Removing the tire from the rear outer dual rim (7-piece Smart rim)1010
Removing the tire from the rear inner dual rim (5-piece rim)1012
Preparation before assembly1013
Installing the tire on the front rim (5-piece rim)1014
Installing the tire on the rear inner dual rim (5-piece rim)1016
Installing the tire on the rear outer dual rim (7-piece Smart rim)1017
Removal and installation of front wheel hub and spindle1018
Removal1018
Spindle removal (off the truck)1024
Installation1026
Disassembly and assembly of front wheel hub and spindle1027
Cross Section View1027
Disassembly1028
Cleaning and inspection1035
Assembly1036
Wheel bearing adjustment1038
Seal assembly gap adjustment1039
Brake seal installation1040
Oil separation seal installation1041
Brake installation1042
Speed sensor installation and adjustment1046
Floating ring seal assembly and installation1048
Removal and installation of rear axle1057
Removal1057
Cleaning and inspection1059
Installation1059
Removal and installation of anti-sway bar1060
Removal1060
Installation1062
Removal and installation of pivot pin1063
Removal1063
Installation1064
Removal and installation of pivot bearing1065
Replacement criteria1065
Removal1067
Inspection1067
Installation1067
Removal and installation of pivot eye1068
Removal1068
Inspection1068
Installation1068
Removal of wheel motor1069
Preparation1069
Installation of wheel motor1071
Cleaning and inspection1071
Installation1072
Removal and installation of rear brake assembly1075
Brake system1077
Removal and installation of brake valve1079
Removal1079
Installation1080
Disassembly and assembly of brake valve/pedal assembly1081
Disassembly1081
Assembly1082
Removal and installation of dual relay valve1085
Removal1085
Installation1086
Removal and installation of brake manifold1087
Removal1087
Installation1087
Disassembly and assembly of brake manifold1088
Disassembly1088
Assembly1088
Removal and installation of piston brake accumulator1089
Removal1089
Installation1091
Disassembly and assembly of piston brake accumulator1093
Disassembly1093
Cleaning and inspection1095
Piston seal replacement1095
Assembly1096
Disassembly and assembly of front wheel brake1097
Disassembly1097
Cleaning and inspection1100
Assembly1101
Disassembly and assembly of rear wheel brake1103
Disassembly1103
Cleaning and inspection1107
Assembly1108
Brake floating ring seal assembly and installation1112
Rear hub floating ring seal assembly and installation1121
Removal and installation of parking brake1127
Removal1127
Installation1129
Disassembly and assembly of parking brake1130
Disassemble and reassemble the brake assembly on a clean, dry work surface The work surface should be wooden If the work surface is metal or concrete, use padding to prevent damage to machined surfaces Handle all parts carefully to avoid damage to1130
Disassembly1130
Cleaning and inspection1132
Cleaning and inspecting new discs1134
Assembly1135
Steering system1137
Removal and installation of steering control unit1139
Removal1139
Installation1141
Disassembly and assembly of steering control unit1142
Disassembly1142
Assembly1144
Removal and installation of steering column1147
Removal1147
Installation1148
Removal and installation of steering wheel1149
Removal1149
Installation1149
Removal and installation of bleeddown manifold1150
Removal1150
Installation1151
Removal and installation of flow amplifier1152
Removal1152
Installation1152
Removal and installation of steering cylinders and tie rod1153
Removal1153
Installation1153
Disassembly and assembly of steering cylinders1155
Disassembly1155
Cleaning and inspection1157
Assembly1157
Removal and installation of steering/brake pump1158
Removal1158
Installation1160
Removal and installation of piston steering accumulator1161
Removal1161
Installation1163
Disassembly and assembly of piston steering accumulator1165
Disassembly1165
Cleaning and inspection1167
Piston seal replacement1167
Assembly1168
Suspensions1171
General information1173
Removal and installation of front suspension1173
Preparation1173
Removal1173
Cleaning and Inspection1175
Installation1176
Disassembly and assembly of front suspension1181
Disassembly1181
Cleaning and inspection1184
Assembly1184
Removal and installation of rear suspension1186
Removal1186
Installation1189
Disassembly and assembly of rear suspension1192
Disassembly1192
Cleaning and inspection1194
Assembly1195
Hoist circuit1197
Removal and installation of hoist pump1199
Removal1199
Installation1203
Disassembly and assembly of hoist pump1204
Disassembly1204
Inspection1209
Assembly1210
Removal and installation of hoist valve1213
Removal1213
Installation1215
Disassembly and assembly of hoist valve1215
O-ring replacement1215
Disassembly of inlet section1217
Assembly of inlet section1218
Disassembly of rear spool section1219
Assembly of rear spool section1221
Disassembly of front spool section1222
Assembly of front spool section1223
Overcenter manifold service1223
Removal and installation of hoist pilot valve1224
Removal1224
Installation1224
Disassembly and assembly of hoist pilot valve1226
Disassembly1226
Cleaning and inspection1227
Assembly1227
Removal and installation of hoist cylinders1228
Removal1228
Installation1230
Disassembly and assembly of hoist cylinders1231
Disassembly1231
Cleaning and inspection1235
Installation of the quill1236
Assembly1238
Body and structures1243
Removal and installation of dump body1245
Removal1245
Inspection1246
Installation1247
Removal and installation of body pads1248
Removal1248
Installation1248
Body pad shimming procedure1249
Removal and installation of diagonal ladder/ hood and grille assembly1250
Removal1250
Installation1250
Removal and installation of RH deck1252
Removal1252
Installation1252
Removal and installation of LH deck1254
Removal1254
Installation1254
Removal and installation of fuel tank (with DEF tank)1256
Removal1256
Cleaning and inspection1256
Installation1258
Removal and installation of fuel gauge sender1258
Removal1258
Installation1258
Removal and installation of hydraulic tank1259
Removal1259
Installation1260
Removal and installation of hydraulic tank strainers1261
Removal1261
Cleaning and inspection1262
Installation1262
Operator cab1265
Removal and installation of operator cab1267
Removal1267
Installation1270
Removal and installation of cab door1270
Removal1270
Installation1271
Disassembly and assembly of cab door1272
Removing the window regulator1272
Installing the window regulator1273
Removing the door glass1274
Installing the door glass1275
Replacing the inner door seal1276
Replacing the outer door seal1276
Removing the interior door handle and door latch (earlier models)1277
Installation and removal of interior door handle and door latch (later models)1280
Adjustment of cab door1282
Door jamb bolt adjustment1282
Exterior door handle release button adjustment1284
Removal and installation of side window glass1285
Recommended tools and supplies1285
Removal1285
Installation1286
Removal and installation of windshield and rear window glass1287
Removal1287
Installation1287
Removal and installation of windshield wiper components1288
Removing the windshield wiper motor1288
Installing the windshield wiper motor1288
Removing the windshield wiper arm and linkage1289
Installing the windshield wiper arm and linkage1290
Removal and installation of cab seats1290
Removal1290
Servicing the seat1291
Installation1291
Removal and installation of seat belts1292
Removal1292
Installation1293
Power module1295
Removal and installation of power module1297
General1297
Removal1298
Installation1307
Exhaust tube installation1310
Exhaust blanket installation1310
Removal and installation of alternator1311
Removal1311
Installation1314
Removal and installation of radiator1325
Removal1325
Installation1330
Repairing the radiator1331
Internal inspection1331
External cleaning1331
Disassembly1331
Cleaning and inspection1332
Assembly1333
Pressure testing1334
Removal and installation of engine1334
Removal1334
Service1334
Installation1335
Removal and installation of electronic fan clutch1336
Removal1336
Installation1337
Removal and installation of electronic fan clutch speed sensor1337
Removal1337
Installation1337
90 Diagrams and drawings1339
Hydraulic circuit diagrams1339
Steering, hoist and brake cooling hydraulic circuit diagram1341
Brake hydraulic circuit diagram1342
Auxiliary system hydraulic circuit schematic1343
Electrical circuit diagrams1346
Electrical diagram1348
HVAC electrical circuit diagram1374

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24