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KOMATUS 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30109 – A30140) KOMATUS 830E 1AC – PDF DOWNLOAD
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- KOMATUS 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30109 – A30140
- PUBLICATION NUMBER:CEBM019602
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KOMATUS 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30109 – A30140) KOMATUS 830E 1AC
KOMATUS 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30109 – A30140) KOMATUS 830E 1AC – PDF DOWNLOAD:
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KOMATUS 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30109 – A30140) KOMATUS 830E 1AC
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing 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, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of metric (SI) and U.S. standard units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lbs) torque. All torque specifications have ±10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- 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 total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATUS 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30109 – A30140) KOMATUS 830E 1AC
COVER .............................................................................................. 1 FOREWORD ........................................................................................... 5 TABLE OF CONTENTS .................................................................................. 7 SECTION A GENERAL INFORMATION ...................................................................... 9 MAJOR COMPONENT DESCRIPTION..................................................................... 11 SPECIFICATIONS.............................................................................. 13 Truck And Engine............................................................................ 11 AC Induction Traction Motorized Wheels...................................................... 11 Suspension.................................................................................. 11 Operator's Cab.............................................................................. 11 Power Steering.............................................................................. 11 Dynamic Retarding........................................................................... 11 Brake System................................................................................ 11 GENERAL SAFETY AND OPERATING INSTRUCTIONS....................................................... 15 GENERAL SAFETY.............................................................................. 19 Safety Rules............................................................................ 19 Truck Safety Features................................................................... 19 Clothing And Personal Items............................................................. 19 Unauthorized Modification............................................................... 19 Leaving The Operator’s Seat............................................................. 19 Mounting And Dismounting................................................................ 20 Fire Extinguishers And First Aid Kits................................................... 20 Precautions For High Temperature Fluids................................................. 20 Asbestos Dust Hazard Prevention......................................................... 20 Fire Prevention For Fuel And Oil........................................................ 21 ROPS Precautions........................................................................ 21 Preventing Injury From Work Equipment................................................... 21 Precautions For Optional Attachments.................................................... 21 Precautions When Starting The Machine................................................... 21 PRECAUTIONS FOR TRUCK OPERATION......................................................... 22 Safety Is Thinking Ahead............................................................ 22 Safety At The Worksite.............................................................. 22 Fire Prevention..................................................................... 22 Preparing For Operation............................................................. 22 Ventilation For Enclosed Areas...................................................... 22 Mirrors, Windows, And Lights........................................................ 23 In The Operator’s Cab - Before Starting The Engine.................................. 23 Seat Belts.......................................................................... 23 OPERATING THE TRUCK..................................................................... 23 Starting The Engine................................................................. 23 Truck Operation - General........................................................... 23 Traveling In The Truck.............................................................. 24 Precautions When Traveling In Reverse............................................... 24 Traveling On Slopes................................................................. 24 Ensuring Good Visibility............................................................ 25 Operating On Snow................................................................... 25 Avoid Damage To The Dump Body....................................................... 25 Driving Near High Voltage Cables.................................................... 25 When Loading The Truck.............................................................. 25 When Dumping........................................................................ 25 Working On Loose Ground............................................................. 26 Parking The Machine................................................................. 26 TOWING.................................................................................. 26 WORKING NEAR BATTERIES.................................................................. 27 Jump Starting With Booster Cables................................................... 28 Jump Starting With Receptacles...................................................... 28 PRECAUTIONS FOR MAINTENANCE................................................................. 29 BEFORE PERFORMING MAINTENANCE........................................................... 29 Stopping The Engine Before Service.................................................. 29 Warning Tag......................................................................... 29 Proper Tools........................................................................ 29 Securing The Dump Body.............................................................. 30 WHILE PERFORMING MAINTENANCE............................................................ 31 Personnel........................................................................... 31 Attachments......................................................................... 31 Working Under The Machine........................................................... 31 Keeping The Machine Clean........................................................... 31 Rules To Follow When Adding Fuel Or Oil............................................. 31 Radiator Coolant Level.............................................................. 31 Use Of Lighting..................................................................... 31 Precautions With The Battery........................................................ 32 Handling High Pressure Hoses........................................................ 32 Precautions With High Pressure Oil.................................................. 32 Maintenance Near High Temperatures And High Pressures............................... 32 Rotating Fan And Belts.............................................................. 32 Waste Materials..................................................................... 32 TIRES................................................................................... 33 Handling Tires...................................................................... 33 Tire Maintenance.................................................................... 34 Storing Tires After Removal......................................................... 34 ADDITIONAL JOB SITE RULES................................................................... 35 WHEN REPAIRS ARE NECESSARY.............................................................. 36 Use of Tie-Off Anchor During Maintenance............................................ 36 SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-1AC TRUCK.................................... 37 Preliminary Procedures before Welding or Performing Maintenance..................... 37 Engine Shutdown Procedure before Welding or Performing Maintenance.................. 37 CAPACITOR DISCHARGE SYSTEM.................................................................. 39 Necessary Tools......................................................................... 39 Warnings And Cautions................................................................... 40 MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE............................................ 41 Preparation......................................................................... 41 CAPACITOR CHARGE LIGHTS................................................................. 43 FAILURE OF DISCHARGE SYSTEM............................................................. 44 Measuring Dc Voltage On Capacitors.................................................. 44 MANUAL DISCHARGE OF CAPACITORS.......................................................... 45 SHORT ISOLATED CAPACITOR TERMINALS...................................................... 47 OPERATING INSTRUCTIONS...................................................................... 49 PREPARING FOR OPERATION................................................................. 49 Safety Is Thinking Ahead............................................................ 49 WALK AROUND INSPECTION.................................................................. 49 ENGINE START-UP SAFETY PRACTICES........................................................ 53 AFTER ENGINE HAS STARTED................................................................ 54 EMERGENCY STEERING SYSTEM............................................................... 55 Operation........................................................................... 55 Pre-Operation Testing............................................................... 55 Additional Guidelines............................................................... 56 MACHINE OPERATION SAFETY PRECAUTIONS.................................................... 56 MACHINE OPERATION ON THE HAUL ROAD...................................................... 57 STARTING ON A GRADE WITH A LOADED TRUCK................................................. 58 PASSING................................................................................. 58 LOADING................................................................................. 58 DUMPING................................................................................. 58 Raising The Dump Body............................................................... 58 Lowering The Dump Body.............................................................. 59 SUDDEN LOSS OF ENGINE POWER............................................................. 61 FUEL DEPLETION.......................................................................... 61 SAFE PARKING PROCEDURES................................................................. 62 NORMAL ENGINE SHUTDOWN PROCEDURE........................................................ 62 DISABLED TRUCK CONNECTORS............................................................... 63 GENERAL............................................................................. 63 STEERING AND BRAKE SYSTEM........................................................... 63 Hookup.......................................................................... 63 HOIST SYSTEM........................................................................ 64 Hookup.......................................................................... 65 Dumping Procedure............................................................... 65 TOWING.............................................................................. 66 Special Wiring Harness.......................................................... 66 Towing Procedure................................................................ 66 RESERVE ENGINE OIL SYSTEM (Optional).................................................... 69 Operation........................................................................... 69 WARNINGS AND CAUTIONS........................................................................... 71 TORQUE TABLES AND CONVERSION CHARTS ............................................................ 83 STORAGE PROCEDURES.............................................................................. 93 STORAGE AND IDLE MACHINE PREPARATION........................................................ 95 SHORT TERM IDLE PERIODS................................................................. 95 PREPARATION FOR STORAGE................................................................. 96 REMOVAL FROM STORAGE.................................................................... 97 RECONDITIONING AN IDLE VEHICLE.......................................................... 99 ENGINE OPERATION........................................................................ 101 AFTER ENGINE HAS STARTED................................................................ 102 ENGINE STORAGE.......................................................................... 103 Engine Storage-(Short Term)......................................................... 103 Engine Storage- (Long Term)......................................................... 104 TRANSMISSION PRESERVATION AND STORAGE................................................... 109 Restoring Transmission to Service................................................... 109 ELECTRIC DRIVE TRUCKS................................................................... 105 SECTION B STRUCTURES ............................................................................... 111 STRUCTURAL COMPONENTS........................................................................... 113 STRUCTURAL COMPONENTS....................................................................... 115 Preparation............................................................................. 115 LADDERS................................................................................. 116 Removal............................................................................. 116 Installation........................................................................ 116 RIGHT DECK.............................................................................. 116 Removal............................................................................. 116 Installation........................................................................ 118 LEFT DECK............................................................................... 118 Removal............................................................................. 118 Installation........................................................................ 119 CENTER DECK............................................................................. 119 DUMP BODY....................................................................................... 121 DUMP BODY................................................................................... 123 Removal................................................................................. 123 Installation............................................................................ 124 BODY PADS............................................................................... 125 Removal............................................................................. 125 Installation........................................................................ 125 Adjustment.......................................................................... 126 BODY GUIDE.............................................................................. 127 BODY-UP RETENTION CABLE................................................................. 128 BODY POSITION INDICATOR................................................................. 128 HOIST LIMIT SWITCH...................................................................... 128 BODY UP SWITCH.......................................................................... 128 ROCK EJECTORS........................................................................... 129 Inspection.......................................................................... 129 FUEL TANK....................................................................................... 131 FUEL TANK................................................................................... 132 Removal................................................................................. 132 Installation............................................................................ 132 Repair.................................................................................. 134 Cleaning................................................................................ 134 FUEL GAUGE SENDER....................................................................... 134 Removal............................................................................. 134 Installation........................................................................ 134 FUEL TANK BREATHER VALVE................................................................ 135 Disassembly......................................................................... 135 Assembly............................................................................ 135 FUEL RECEIVERS (WIGGINS QUICK FILL)..................................................... 135 FUEL RECEIVERS (WIGGINS QUICK FILL)..................................................... 136 SECTION C ENGINE ................................................................................... 137 POWER MODULE.................................................................................... 139 POWER MODULE................................................................................ 141 PREPARATION............................................................................. 141 Removal............................................................................. 141 Installation........................................................................ 146 COOLING SYSTEM.................................................................................. 151 COOLING SYSTEM DESCRIPTION.................................................................. 153 RADIATOR................................................................................ 154 Removal............................................................................. 154 Installation........................................................................ 157 Radiator Filling Procedure.......................................................... 158 REPAIRING THE RADIATOR...................................................................... 159 Internal Inspection..................................................................... 159 External Cleaning....................................................................... 159 Disassembly............................................................................. 159 Cleaning and Inspection................................................................. 160 Assembly................................................................................ 160 Pressure Testing........................................................................ 162 COOLANT SYSTEM TROUBLESHOOTING.............................................................. 162 POWER TRAIN..................................................................................... 163 ALTERNATOR REMOVAL PROCEDURE................................................................ 165 Removal (Komatsu SSDA16V160 or SDA16V160 Engine)........................................ 165 ENGINE/ALTERNATOR MATING.................................................................... 167 General Instructions.................................................................... 167 Measuring Procedure..................................................................... 167 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine........................... 169 ENGINE...................................................................................... 170 Removal................................................................................. 170 Service................................................................................. 171 Installation............................................................................ 171 AIR CLEANERS.................................................................................... 173 AIR CLEANERS................................................................................ 175 OPERATION............................................................................... 175 SERVICING THE AIR CLEANERS.............................................................. 175 Replacing The Filter Element........................................................ 176 AIR CLEANER ASSEMBLY CLEANING........................................................... 177 Main Filter Cleaning................................................................ 177 Precleaner Section Cleaning......................................................... 179 AIR INTAKE TROUBLESHOOTING.............................................................. 180 FAN CLUTCH ..................................................................................... 181 FAN CLUTCH.................................................................................. 183 REMOVAL & INSTALLATION TOOLING.......................................................... 183 DISASSEMBLY............................................................................. 186 CLEANING AND INSPECTION................................................................. 196 ASSEMBLY................................................................................ 200 TEST PROCEDURE.......................................................................... 214 SECTION D ELECTRICAL SYSTEM (24VDC) ................................................................ 215 24VDC ELECTRIC SUPPLY SYSTEM.................................................................... 217 24VDC ELECTRIC SUPPLY SYSTEM................................................................ 219 ELECTRICAL SYSTEM DESCRIPTION........................................................... 219 BATTERIES............................................................................... 219 Maintenance and Service............................................................. 219 Troubleshooting..................................................................... 219 BATTERY SUPPLY SYSTEM................................................................... 221 24VDC Battery Charging Alternator................................................... 221 Battery Box......................................................................... 221 Battery Control Box................................................................. 222 Battery Disconnect Switches......................................................... 222 24VDC Auxiliary Battery Receptacles................................................. 222 Isolator Diode...................................................................... 222 Engine Start Relay.................................................................. 222 24VDC to 12VDC Converter............................................................ 222 24 VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE).................................... 223 Operation........................................................................... 223 Pressure Switch..................................................................... 224 Check Valve......................................................................... 224 Timer Solenoid...................................................................... 224 MAINTENANCE............................................................................. 224 Prelube System Operation Checks..................................................... 224 Check Valve......................................................................... 224 Timer Solenoid...................................................................... 224 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT.............................................. 225 24 VDC ELECTRIC START SYSTEM................................................................ 227 CRANKING MOTORS......................................................................... 227 Operation........................................................................... 227 Removal............................................................................. 227 Installation........................................................................ 227 CRANKING MOTOR TROUBLESHOOTING.......................................................... 228 Preliminary Inspection.............................................................. 228 No-Load Test........................................................................ 228 Interpreting Results of Tests....................................................... 229 Disassembly......................................................................... 229 Cleaning and Inspection............................................................. 230 Armature Servicing.................................................................. 232 Field Coil Checks................................................................... 232 Field Coil Removal.................................................................. 232 SOLENOID CHECKS......................................................................... 233 Test................................................................................ 233 Assembly............................................................................ 234 Bearing Replacement:................................................................ 234 Motor Assembly:..................................................................... 234 Pinion Clearance.................................................................... 235 MAGNETIC SWITCH......................................................................... 235 Removal............................................................................. 235 Installation........................................................................ 235 Coil Test........................................................................... 236 24VDC ELECTRICAL SYSTEM COMPONENTS.............................................................. 237 24 VDC ELECTRICAL SYSTEM COMPONENTS......................................................... 239 TRUCK SHUTDOWN PROCEDURE................................................................ 239 BRAKE WARNING BUZZER.................................................................... 239 AUXILIARY CONTROL CABINET COMPONENTS.................................................... 239 Power Distribution Terminals........................................................ 239 Pulse Voltage Modulator (PMV)....................................................... 240 Control Power Relay................................................................. 240 Auto Lube Timer..................................................................... 240 Ground Level Power Relay............................................................ 240 Diode Board - DB1................................................................... 242 Fuse Blocks......................................................................... 243 Alarm Indicating Device (AID) System................................................ 243 Diode Matrix (With Sound)........................................................... 244 Diode Matrix (Without Sound)........................................................ 244 Hot Switch Inverter................................................................. 244 Hot Switch Inverter (Not Used)...................................................... 245 Temperature and Latch............................................................... 245 RELAY BOARDS............................................................................ 246 Relay Boards RB1, RB3, RB4, RB5..................................................... 246 Relay Boards RB6, RB7, RB8, RB9..................................................... 247 Service............................................................................. 247 Relay Board Functions............................................................... 249 BODY-UP SWITCH.......................................................................... 251 Operation........................................................................... 251 Adjustment.......................................................................... 251 Service............................................................................. 251 HOIST LIMIT SWITCH...................................................................... 252 Operation........................................................................... 252 Adjustment.......................................................................... 252 Service............................................................................. 252 FUSE BLOCK CHARTS....................................................................... 253 CIRCUIT BREAKER CHART................................................................... 255 CIRCUIT BREAKERS........................................................................ 255 BATTERY CHARGING ALTERNATOR .................................................................... 257 BATTERY CHARGING SYSTEM..................................................................... 261 BATTERY CHARGING SYSTEM................................................................. 261 ELECTRICAL SYSTEM DESCRIPTION....................................................... 261 CHARGE VOLT AND AMP VALUES.......................................................... 261 BATTERY............................................................................. 261 Maintenance and Service......................................................... 261 Troubleshooting................................................................. 262 Undercharging................................................................... 262 Overcharging.................................................................... 262 Corrosion....................................................................... 262 Acid Levels..................................................................... 262 Non-Use or Storage.............................................................. 262 Freezing........................................................................ 263 BATTERY CHARGING ALTERNATOR............................................................. 264 GENERAL INFORMATION................................................................. 264 General Description............................................................. 264 Terminal Identification and Location............................................ 265 Battery Positive (B+)........................................................... 265 Battery Negative (B-)........................................................... 265 DC Output (D+).................................................................. 265 AC Output (R)................................................................... 265 Regulator Harness Plug Identification........................................... 265 Alternator Specifications....................................................... 265 Performance Curve............................................................... 265 Battery/Alternator Terminology.................................................. 266 WIRING DIAGRAM...................................................................... 268 DIMENSIONS AND TORQUE VALUES........................................................ 269 PERIODIC MAINTENANCE................................................................ 270 TESTING................................................................................. 270 GENERAL INFORMATION................................................................. 270 Troubleshooting Alternator (On-Truck)........................................... 270 Equipment Required.............................................................. 270 Preliminary Checks.............................................................. 270 Test Set-up..................................................................... 272 Test Procedure.................................................................. 273 REGULATOR TESTING................................................................... 274 Regulator Bypass Test (No Output)............................................... 274 Regulator Bypass Test (Amp Rating).............................................. 275 BENCH TESTING....................................................................... 276 Equipment....................................................................... 276 Identification Record........................................................... 276 Advanced Troubleshooting........................................................ 276 Bench Test 1: No-Load Test...................................................... 276 Bench Test 2: Full Load Test.................................................... 277 Bench Test 3: Regulator Bypass Test............................................. 277 STATIC TESTING...................................................................... 278 Equipment....................................................................... 278 Identification Record........................................................... 278 Regulator Tester................................................................ 278 Check For Shorted Power Transistor.............................................. 278 Circuit Tests................................................................... 279 FIELD COIL TESTS.................................................................... 280 Field Coil Test 1: Check for Open or Shorted Field Coil......................... 280 Field Coil Test 2: Check For Grounded Field Coil................................ 280 STATOR TESTS........................................................................ 281 Stator Test 1: Check For Stator-To-Stator Continuity............................ 281 Stator Test 2: Check For Grounded Stators....................................... 282 THERMAL SWITCH TEST................................................................. 282 Initial Test.................................................................... 282 Verifying a Faulty Thermal Switch............................................... 283 TROUBLESHOOTING TIPS................................................................ 284 ALTERNATOR.............................................................................. 288 ALTERNATOR REPAIR................................................................... 288 Removal......................................................................... 288 Installation.................................................................... 290 Special Tools and Lubricants.................................................... 290 Epoxy Adhesive.................................................................. 291 Liquid Threadlockers............................................................ 291 Elastoplastic Silicone Resin.................................................... 291 ALTERNATOR EXPLODED VIEW............................................................ 293 ALTERNATOR DISASSEMBLY.............................................................. 295 Regulator Removal............................................................... 295 Fan Removal..................................................................... 296 Pulley Removal.................................................................. 297 Anti-Drive End Housing Removal.................................................. 297 Anti-Drive End Rotor Removal.................................................... 299 Drive End Housing Removal....................................................... 301 Drive End Rotor Removal......................................................... 307 Field Coil Removal.............................................................. 308 Drive End and/or Anti-Drive End Stator Removal.................................. 310 CLEANING AND INSPECTION............................................................. 312 ALTERNATOR ASSEMBLY................................................................. 312 Anti-Drive End Stator Installation.............................................. 312 Drive End Stator Installation................................................... 314 Field Coil Installation......................................................... 317 Drive End Bearing Installation.................................................. 319 Drive End Rotor Installation.................................................... 321 Rotor and Rotor Shaft Installation.............................................. 321 Drive End Housing Installation.................................................. 322 Anti-Drive End Rotor Installation............................................... 326 Anti-Drive End Housing Installation............................................. 327 Regulator Installation.......................................................... 330 THERMAL SWITCH...................................................................... 331 Removal......................................................................... 331 Installation.................................................................... 333 SUPPORT STAND....................................................................... 333 KOMTRAX Plus SYSTEM ............................................................................ 335 KOMTRAX Plus COMPONENTS..................................................................... 337 KOMTRAX Plus BASIC FEATURES............................................................. 337 Gather Data......................................................................... 337 Convert and Record Data............................................................. 337 Communicate Data to Off-Board Systems............................................... 338 USING THE KOMTRAX Plus SYSTEM........................................................... 339 Turning the KOMTRAX Plus System ON.................................................. 339 Normal KOMTRAX Plus Operation....................................................... 339 Turning the KOMTRAX Plus System OFF................................................. 340 Downloading from the KOMTRAX Plus Controller........................................ 340 KOMTRAX Plus DATA ITEMS................................................................. 341 Fault Codes......................................................................... 341 Machine History..................................................................... 341 KOMTRAX Plus History................................................................ 341 Snapshots........................................................................... 342 Manual Snapshots.................................................................... 342 Trends.............................................................................. 344 Histogram (Load Map) Data........................................................... 344 Haul Cycle Data..................................................................... 345 Alarm and Snapshot Triggers......................................................... 346 Satellite Features.................................................................. 346 KOMTRAX Plus DIAGNOSTIC FEATURES........................................................ 348 Fault History....................................................................... 348 KOMTRAX Plus LED Digits............................................................. 348 KOMTRAX Plus CONTROLLER................................................................. 348 Removal............................................................................. 349 Installation........................................................................ 349 KOMTRAX Plus SOFTWARE....................................................................... 351 NECESSARY SOFTWARE...................................................................... 351 NECESSARY TOOLS......................................................................... 351 KOMTRAX Plus SYSTEM SET UP.............................................................. 352 KOMTRAX Plus Controller............................................................. 352 KOMTRAX Plus CONTROLLER................................................................. 352 KOMTRAX Plus TOOL BOX............................................................... 352 Installation.................................................................... 352 KOMTRAX Plus SETTING TOOL........................................................... 352 Installation.................................................................... 352 KOMTRAX Plus INITIALIZATION PROCEDURE................................................... 353 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE.......................................... 353 KOMTRAX Plus Setting Tool software program...................................... 353 Select Operation................................................................ 353 KOMTRAX Plus Setting Function................................................... 354 Machine Information Setting(1).................................................. 354 Machine Information Setting(2).................................................. 354 Date & Time Setting............................................................. 354 GCC Setting..................................................................... 355 Setting Summary................................................................. 355 2. KOMTRAX Plus SNAPSHOT PROCEDURE.................................................. 356 3. KOMTRAX Plus DOWNLOAD PROCEDURE.................................................. 357 4. LOCATION OF DOWNLOAD FILES....................................................... 357 5. KOMTRAX Plus FTP UPLOAD PROCEDURE................................................ 358 6. KOMTRAX Plus INITIALIZATION FORMS................................................ 359 WHEN REPLACING A KOMTRAX Plus CONTROLLER................................................ 360 To Set: Date & Time; Satellite; Payload Meter....................................... 362 Review Setting Information.......................................................... 364 KOMTRAX Plus CONTROLLER CHECKOUT.................................................... 365 KOMTRAX Plus Controller......................................................... 365 Necessary Equipment:............................................................ 365 Preliminary..................................................................... 366 KOMTRAX Plus Controller Checkout Procedure...................................... 367 ORBCOMM CONTROLLER.................................................................. 369 Removal......................................................................... 369 Installation.................................................................... 369 INTERFACE MODULE ............................................................................... 371 INTERFACE MODULE............................................................................ 373 Removal................................................................................. 373 Installation............................................................................ 373 SENSORS................................................................................. 374 Temperature Sensors................................................................. 374 Pressure Sensors.................................................................... 374 INTERFACE MODULE SOFTWARE................................................................... 375 NECESSARY SOFTWARE...................................................................... 375 NECESSARY TOOLS......................................................................... 375 FLASHBURN PROGRAM....................................................................... 376 Installation........................................................................ 376 INTERFACE MODULE APPLICATION CODE....................................................... 376 Installation........................................................................ 376 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM................................. 376 Installation........................................................................ 376 Using The Program................................................................... 376 INTERFACE MODULE CHECKOUT............................................................... 377 Interface Module.................................................................... 377 Necessary Equipment:................................................................ 377 Preliminary......................................................................... 378 Checking Inputs And Outputs From The Interface Module............................... 378 Check Analog Inputs To The Interface Module......................................... 382 Check CAN RPC & J1939 Interfaces To The IM.......................................... 382 Check Outputs From The Interface Module............................................. 382 KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES ................................ 385 KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING........................... 387 TROUBLESHOOTING......................................................................... 387 GENERAL............................................................................. 387 Structure and Purpose........................................................... 387 TROUBLESHOOTING..................................................................... 388 Communications Networks......................................................... 388 Coaxial Cable................................................................... 388 FAULT CODES......................................................................... 389 Fault History................................................................... 389 KOMTRAX Plus LED Display Fault Codes............................................ 390 Chassis Fault Codes............................................................. 391 Engine Fault Codes.............................................................. 395 FAULT TREE ANALYSIS................................................................. 401 Unable to connect to KOMTRAX Plus from laptop PC................................ 401 Flashing Error Code N4-23 (PLM III Communications Fault)........................ 402 Flashing Error Code N4-22 (Engine Communications Fault)......................... 403 No Data Received By WebCARE..................................................... 404 Coaxial Cable Troubleshooting................................................... 405 KOMTRAX PLUS FORMS ............................................................................. 407 KOMTRAX PLUS FORMS.......................................................................... 409 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 409 KOMTRAX PLUS DATA DOWNLOAD.............................................................. 410 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 411 KOMTRAX PLUS INITIALIZATION FORM........................................................ 413 SECTION E ELECTRIC PROPULSION SYSTEM ............................................................... 415 ELECTRIC PROPULSION SYSTEM COMPONENTS .......................................................... 417 ELECTRICAL PROPULSION SYSTEM COMPONENTS..................................................... 419 GENERAL SYSTEM DESCRIPTION.............................................................. 419 SYSTEM COMPONENTS....................................................................... 421 Propulsion System Controller (PSC).................................................. 421 Truck Control Interface (TCI)....................................................... 422 Diagnostic Information Display (DID) Panel.......................................... 423 DID Panel Event Codes............................................................... 423 PSC SOFTWARE FUNCTIONS.................................................................. 442 Input Processing.................................................................... 442 State Machine....................................................................... 442 DC Link State....................................................................... 445 Engine Control...................................................................... 446 ALTERNATOR FIELD CONTROL................................................................ 446 Desired Three-Phase Voltage......................................................... 446 Desired DC Link Voltage............................................................. 446 Self-Load........................................................................... 447 Propel Torque Control............................................................... 447 Retard Torque Control............................................................... 447 Wheel Slide Control................................................................. 448 Resistor Grid Control............................................................... 448 Chopper Voltage Control............................................................. 448 EVENT DETECTION AND PROCESSING.......................................................... 448 Power-On Tests...................................................................... 448 Initiated Tests..................................................................... 449 Periodic Tests...................................................................... 449 EVENT RESTRICTIONS...................................................................... 449 EVENT LOGGING AND STORAGE............................................................... 449 Event History Buffer................................................................ 450 Data Packs.......................................................................... 450 To Record and Save a Data Pack to a Disk............................................ 450 Event Reset......................................................................... 451 SERIAL DATA COMMUNICATIONS.............................................................. 451 PSC - TCI Communications Processing................................................. 451 PSC - PTU Communications Processing................................................. 451 Inverter Communications Processing.................................................. 452 OUTPUT PROCESSING....................................................................... 452 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS................................................ 452 Fast Start.......................................................................... 452 Engine Shutdown/Engine Not Running.................................................. 452 Limp Home Mode...................................................................... 453 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS................................... 454 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 462 Removal............................................................................. 462 Installation........................................................................ 462 Disassembly......................................................................... 462 Assembly............................................................................ 462 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE .................................................. 463 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................................... 465 AC DRIVE SYSTEM MAINTENANCE............................................................. 465 NORMAL TRUCK SHUTDOWN PROCEDURE......................................................... 466 SHUTDOWN AFTER SYSTEM FAILURE........................................................... 466 SYSTEM CHECKOUT......................................................................... 467 Battery and Control Circuit Checks - Battery Power OFF.............................. 467 Battery and Control Circuit Checks - Battery Power ON............................... 470 Checks with Key Switch OFF.......................................................... 471 Checks with Key Switch ON........................................................... 471 CPU Battery Checks.................................................................. 471 MEMORY BACKUP BATTERY REPLACEMENT....................................................... 472 TCI PROGRAMMING......................................................................... 472 PSC PROGRAMMING......................................................................... 473 INVERTER PROGRAMMING.................................................................... 473 CPU RESET............................................................................... 473 PSC CHECKOUT............................................................................ 474 PSC Digital Input Checks............................................................ 474 PSC Digital Output Checks........................................................... 478 TCI CHECKOUT............................................................................ 479 Modular Mining Communication Port Check............................................. 479 TCI Digital Input Checks............................................................ 479 TCI Digital Output Tests............................................................ 485 CALIBRATIONS............................................................................ 487 Speedometer......................................................................... 487 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial................................ 487 ERASING EVENTS.......................................................................... 487 PSC................................................................................. 487 TCI................................................................................. 488 GATE DRIVER POWER CONVERTER TEST........................................................ 488 LOAD TESTING............................................................................ 489 Preparation......................................................................... 489 Alternator Speed Sensor Checks...................................................... 489 Battery Boost Check................................................................. 489 Brake Circuit Switch Checks......................................................... 490 Hoist & Steering Circuit Switch Checks.............................................. 490 Link Energized Checks............................................................... 490 Loadbox Test........................................................................ 492 TROUBLESHOOTING......................................................................... 496 PVM Optimum Load Curve Handshaking Troubleshooting.................................. 496 Phase Module and Chopper Module Troubleshooting..................................... 496 PHASE MODULE REPLACEMENT................................................................ 497 Phase Module Removal................................................................ 497 Phase Module Installation........................................................... 497 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS .......................................................... 499 TIRES AND RIMS.................................................................................. 501 TIRES AND RIMS.............................................................................. 503 FRONT TIRES AND RIMS.................................................................... 503 Removal............................................................................. 503 Installation........................................................................ 505 REAR TIRES AND RIMS..................................................................... 505 Removal............................................................................. 505 Installation........................................................................ 506 RIM AND TIRE............................................................................ 508 Tire Removal........................................................................ 508 Rim And Tire Preparation............................................................ 508 Lubricants.......................................................................... 509 Tire Installation................................................................... 509 FRONT WHEEL HUB AND SPINDLES.................................................................... 511 FRONT WHEEL HUB AND SPINDLE................................................................. 513 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 513 Removal............................................................................. 513 Spindle Removal Procedure (Optional) (off of the truck)............................. 516 Installation........................................................................ 518 Disassembly......................................................................... 521 Cleaning and Inspection............................................................. 521 Assembly............................................................................ 522 Wheel Bearing Adjustment (Tire Removed)............................................. 524 Wheel Bearing Adjustment (Tire mounted)............................................. 525 OIL SAMPLING PROCEDURE.................................................................. 526 Oil Sampling Guidelines............................................................. 527 Procedure........................................................................... 527 OIL DRAIN AND REFILL PROCEDURE.......................................................... 527 STEERING CYLINDERS...................................................................... 528 Spherical Bearing Wear Limits....................................................... 528 Removal............................................................................. 529 Installation........................................................................ 529 Bearing Replacement (Steering cylinder and tie rod)................................. 529 TIE ROD................................................................................. 531 Removal............................................................................. 531 Installation........................................................................ 531 Disassembly......................................................................... 531 Assembly............................................................................ 532 TOE-IN ADJUSTMENT....................................................................... 533 REAR AXLE HOUSING ATTACHMENT.................................................................... 535 REAR AXLE HOUSING ATTACHMENT................................................................ 537 PIVOT PIN............................................................................... 537 Removal............................................................................. 537 Installation........................................................................ 537 PIVOT EYE BEARING....................................................................... 538 Disassembly......................................................................... 538 Assembly............................................................................ 538 PIVOT EYE REPAIR........................................................................ 539 Removal............................................................................. 539 Installation........................................................................ 539 Disassembly......................................................................... 539 Assembly............................................................................ 539 ANTI-SWAY BAR........................................................................... 540 Removal............................................................................. 540 Installation........................................................................ 540 Disassembly......................................................................... 540 Cleaning and Inspection............................................................. 540 Assembly............................................................................ 540 REAR AXLE HOUSING............................................................................... 541 REAR AXLE HOUSING........................................................................... 543 REAR AXLE HOUSING....................................................................... 543 Removal............................................................................. 543 Installation........................................................................ 543 WHEEL MOTOR............................................................................. 544 Removal............................................................................. 544 Cleaning and Inspection............................................................. 544 Installation........................................................................ 545 WHEEL MOTOR GEAR OIL.................................................................... 548 Change/Filter The Gear case Oil..................................................... 548 Oil................................................................................. 548 Remove And Clean Magnetic Plugs..................................................... 548 Flushing The Gearbox................................................................ 548 Check Gear Case Oil Level........................................................... 548 SECTION H SUSPENSIONS .............................................................................. 549 FRONT SUSPENSION................................................................................ 551 FRONT SUSPENSION............................................................................ 553 Removal................................................................................. 553 Installation............................................................................ 554 TURN-OF-THE-NUT Tightening Procedure.................................................... 556 Upper Mounting Joint - 60° Advance.................................................. 556 Lower Mounting Joint - 90° Advance.................................................. 558 Inspection.......................................................................... 558 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)..................................... 559 Bearing Structure Removal........................................................... 559 Bearing Structure Installation...................................................... 559 MAJOR SUSPENSION REBUILD................................................................ 560 Disassembly......................................................................... 560 Assembly............................................................................ 561 PRESSURE TEST........................................................................... 563 REAR SUSPENSIONS ............................................................................... 565 REAR SUSPENSIONS............................................................................ 567 Removal................................................................................. 567 Installation............................................................................ 570 ROD UP SUSPENSION....................................................................... 572 Disassembly......................................................................... 572 Cleaning and Inspection............................................................. 572 Assembly............................................................................ 572 ROD DOWN SUSPENSION..................................................................... 574 Disassembly......................................................................... 574 Cleaning and Inspection............................................................. 574 Assembly............................................................................ 576 PRESSURE TEST........................................................................... 578 Suspension pressure test............................................................ 578 OILING AND CHARGING PROCEDURE................................................................... 579 OILING AND CHARGING PROCEDURE............................................................... 581 GENERAL................................................................................. 581 EQUIPMENT LIST.......................................................................... 581 HYDRAIR® CHARGING KIT................................................................... 582 Installation of Charging Kit........................................................ 582 Removal of Charging Kit............................................................. 582 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................................... 583 FRONT SUSPENSION........................................................................ 583 Front Suspension Oiling............................................................. 583 Front Suspension Nitrogen Charging.................................................. 585 REAR SUSPENSION - ROD UP................................................................ 587 Rear Suspension Oiling (Rod Up Only)................................................ 587 Rear Suspension Nitrogen Charging (Rod Up Only)..................................... 588 REAR SUSPENSION - ROD DOWN.............................................................. 590 Rear Suspension Oiling (Rod Down Only).............................................. 590 Rear Suspension Nitrogen Charging (Rod Down Only)................................... 592 OIL AND NITROGEN SPECIFICATIONS CHART................................................... 594 SECTION J BRAKE CIRCUIT ............................................................................ 595 BRAKE CIRCUIT................................................................................... 597 BRAKE CIRCUIT............................................................................... 599 OPERATION............................................................................... 599 SERVICE BRAKE CIRCUIT OPERATION......................................................... 599 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 601 PARKING BRAKE CIRCUIT................................................................... 601 Normal Operation (key switch on, engine running).................................... 601 BRAKE LOCK CIRCUIT...................................................................... 602 WARNING CIRCUIT......................................................................... 602 BRAKE CIRCUIT COMPONENT SERVICE................................................................. 605 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 607 BRAKE VALVE............................................................................. 607 Rebuild Criteria.................................................................... 607 Removal............................................................................. 607 Installation........................................................................ 609 DISASSEMBLY............................................................................. 611 Cleaning and Inspection............................................................. 613 ASSEMBLY................................................................................ 613 Actuator Base Threaded Inserts...................................................... 613 Boot and Cap........................................................................ 613 Valve Body Seal Installation........................................................ 614 Regulator Sleeve O-Ring Installation................................................ 614 Actuator Plunger O-ring Installation................................................ 615 Assembly of Valve................................................................... 615 VALVE BENCH TEST AND ADJUSTMENT......................................................... 617 Test Set Up Procedure............................................................... 618 Brake Valve Output Pressure Adjustment.............................................. 618 Final Test and Adjustment........................................................... 619 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 620 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal).... 622 Installation of Retard Pedal To Brake Pedal......................................... 622 HYDRAULIC BRAKE ACCUMULATORS............................................................ 623 Brake Accumulator Bleed Down Procedure.............................................. 623 Removal............................................................................. 623 Installation........................................................................ 623 Disassembly......................................................................... 623 Cleaning and Inspection............................................................. 625 Assembly............................................................................ 625 Charging Procedure.................................................................. 627 BRAKE MANIFOLD.......................................................................... 628 Removal............................................................................. 628 Removal............................................................................. 628 Installation........................................................................ 629 Disassembly......................................................................... 629 Cleaning and Inspection............................................................. 630 Assembly............................................................................ 630 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................... 631 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 633 EQUIPMENT REQUIRED...................................................................... 634 INITIAL SYSTEM SET-UP................................................................... 636 PARKING BRAKE........................................................................... 636 BRAKE SYSTEM CHECK-OUT.................................................................. 637 BRAKE LOCK.............................................................................. 637 FAILURE MODES CHECK-OUT................................................................. 638 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 639 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 642 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 643 FRONT BRAKES.................................................................................... 645 WHEEL SPEED FRONT DISC BRAKES............................................................... 647 BRAKE CALIPER........................................................................... 647 Caliper Removal..................................................................... 647 Installation........................................................................ 648 Disassembly......................................................................... 649 Assembly............................................................................ 649 Cleaning and Inspection............................................................. 650 BRAKE LINING............................................................................ 651 Replacement......................................................................... 651 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................. 653 GENERAL............................................................................. 653 Safety Precautions.............................................................. 653 Front Brake Conditioning........................................................ 653 BRAKE BLEEDING PROCEDURES............................................................... 654 ARMATURE SPEED REAR DISC BRAKES................................................................. 655 ARMATURE SPEED REAR DISC BRAKES............................................................. 657 REAR BRAKES............................................................................. 657 CALIPER AND DISC.................................................................... 657 Removal......................................................................... 657 Installation.................................................................... 659 PARK BRAKE ADJUSTMENT PROCEDURE..................................................... 661 BRAKE BLEEDING PROCEDURE............................................................ 662 Service Brake................................................................... 662 Park Brake...................................................................... 662 CALIPER............................................................................. 663 Disassembly..................................................................... 663 PISTON SUBASSEMBLY.................................................................. 666 Disassembly..................................................................... 666 PREPARATION FOR ASSEMBLY............................................................ 667 Clean Parts..................................................................... 667 For Rough Metal Parts........................................................... 668 Dry and Inspect Parts........................................................... 668 Corrosion Protection............................................................ 668 INSPECTION.......................................................................... 668 Caliper Parts................................................................... 668 Shoes, Linings and End Plates................................................... 669 Inspect linings................................................................. 669 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC).................... 669 Piston Assembly Adjuster Grip Force............................................. 670 Adjuster Force.................................................................. 672 Piston Return Spring............................................................ 674 ASSEMBLY............................................................................ 675 Adjuster and Pin Assembly....................................................... 675 Piston Subassembly.............................................................. 676 Brake Caliper................................................................... 677 PERIODIC INSPECTIONS................................................................ 683 Shoes, Linings and End Plates................................................... 683 Inspect the following areas for fluid leaks..................................... 683 Dust Boots...................................................................... 683 Brake Disc...................................................................... 683 BRAKE LINING........................................................................ 684 Replacement..................................................................... 684 BRAKE DISC.......................................................................... 684 Inspection...................................................................... 684 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................... 685 GENERAL......................................................................... 685 SAFETY PRECAUTIONS.............................................................. 685 Rear Brake Conditioning..................................................... 686 SECTION L HYDRAULIC SYSTEM......................................................................... 689 HYDRAULIC SYSTEM................................................................................ 691 HYDRAULIC SYSTEM............................................................................ 693 HYDRAULIC SYSTEM OPERATION.............................................................. 693 COMPONENT DESCRIPTION................................................................... 694 Hoist Pump.......................................................................... 694 Steering/Brake Pump................................................................. 694 Tank................................................................................ 694 High Pressure Hydraulic Filters..................................................... 694 Bleeddown Manifold.................................................................. 694 Steering System Accumulators........................................................ 694 DISABLED TRUCK CONNECTORS............................................................... 696 GENERAL............................................................................. 696 STEERING AND BRAKE SYSTEM........................................................... 696 Hookup.......................................................................... 696 HOIST SYSTEM........................................................................ 697 Hookup.......................................................................... 697 Dumping Procedure............................................................... 697 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................... 699 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 701 HOIST PUMP.............................................................................. 701 Removal............................................................................. 701 Installation........................................................................ 702 Disassembly......................................................................... 704 Inspection Of Parts................................................................. 707 Assembly............................................................................ 708 HYDRAULIC TANK.......................................................................... 714 Filling Instructions................................................................ 714 Removal............................................................................. 714 Installation........................................................................ 715 HYDRAULIC TANK STRAINERS................................................................ 716 Removal............................................................................. 716 Inspect and Clean................................................................... 716 Installation........................................................................ 717 HYDRAULIC TANK BREATHERS................................................................ 717 HOIST CIRCUIT FILTERS................................................................... 718 FILTER ELEMENT REPLACEMENT.............................................................. 719 Removal............................................................................. 719 Installation........................................................................ 719 INDICATOR SWITCH........................................................................ 719 STEERING CIRCUIT................................................................................ 721 STEERING CIRCUIT............................................................................ 723 STEERING CIRCUIT OPERATION.............................................................. 723 COMPONENT DESCRIPTION................................................................... 724 STEERING CONTROL UNIT............................................................... 724 FLOW AMPLIFIER...................................................................... 724 No Steer........................................................................ 726 Steering Left................................................................... 728 Steering Right.................................................................. 730 No Steer, External Shock Load................................................... 732 BLEED DOWN MANIFOLD................................................................. 734 ACCUMULATORS........................................................................ 735 Low Precharge Warning Switch.................................................... 735 HIGH PRESSURE FILTER................................................................ 735 STEERING/BRAKE PUMP................................................................. 735 Operation....................................................................... 736 PRINCIPLE OF OPERATION.............................................................. 738 Full Pump Volume:............................................................... 738 Half Pump Volume:............................................................... 738 Neutral Position:............................................................... 739 STEERING CIRCUIT COMPONENT REPAIR............................................................... 741 STEERING CIRCUIT COMPONENT REPAIR........................................................... 743 BLEED DOWN MANIFOLD..................................................................... 743 Removal............................................................................. 743 Installation........................................................................ 743 ACCUMULATOR............................................................................. 744 Removal............................................................................. 744 Installation........................................................................ 745 Disassembly......................................................................... 745 Cleaning and Inspection............................................................. 746 Assembly............................................................................ 746 LEAK TESTING............................................................................ 748 STEERING ACCUMULATOR CHARGING PROCEDURE................................................. 749 Temperature During Precharge........................................................ 752 ACCUMULATOR STORAGE PROCEDURES.......................................................... 752 Instructions For Storing Bladder Accumulators....................................... 752 Installation........................................................................ 753 Bladder Storage Procedures.......................................................... 753 FLOW AMPLIFIER.......................................................................... 754 Removal............................................................................. 754 Installation........................................................................ 754 Disassembly......................................................................... 756 Reassembly.......................................................................... 757 STEERING CONTROL UNIT................................................................... 758 Removal............................................................................. 758 Spline Inspection................................................................... 758 Installation........................................................................ 759 Disassembly......................................................................... 759 Cleaning and Inspection............................................................. 760 Assembly............................................................................ 761 STEERING CYLINDER....................................................................... 765 Disassembly......................................................................... 765 Inspection and Cleaning............................................................. 765 Assembly............................................................................ 765 STEERING CIRCUIT FILTER................................................................. 766 Filter Element Replacement.......................................................... 766 Removal............................................................................. 767 Installation........................................................................ 767 Indicator Switch.................................................................... 767 STEERING AND BRAKE PUMP................................................................. 768 Removal............................................................................. 768 Installation........................................................................ 769 Disassembly......................................................................... 770 Control Piston Group................................................................ 770 Valve Plate Group................................................................... 771 Rotating Group...................................................................... 771 Swashblock Group.................................................................... 772 Driveshaft Group.................................................................... 772 INSPECTION.............................................................................. 772 Control Piston Group................................................................ 772 Valve Plate Group................................................................... 772 Rotating Group...................................................................... 772 Swashblock Group.................................................................... 776 Driveshaft Group.................................................................... 776 Compensator Block and Unloader Module............................................... 776 Stroke Adjuster Assembly............................................................ 776 ASSEMBLY................................................................................ 776 Swashblock Group.................................................................... 776 Control Piston Group................................................................ 778 Valve Plate Group................................................................... 779 HOIST CIRCUIT................................................................................... 781 HOIST CIRCUIT............................................................................... 783 HOIST CIRCUIT OPERATION................................................................. 783 COMPONENT DESCRIPTION................................................................... 784 Hydraulic Tank...................................................................... 784 Hoist Pump.......................................................................... 784 High Pressure Filters............................................................... 784 Hoist Valve......................................................................... 785 Hoist Pilot Valve................................................................... 786 Hoist-up Limit Solenoid............................................................. 786 Pilot Operated Check Valve.......................................................... 786 Counterbalance Valve Manifold....................................................... 787 HOIST SYSTEM OPERATION MODES............................................................ 788 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)........................ 788 Power Up Operation (Figure 7-7)..................................................... 790 Hold Operation (Figure 7-8)......................................................... 792 Power Down Operation (Figure 7-9)................................................... 794 Float Operation (Figure 7-10)....................................................... 796 HOIST CIRCUIT COMPONENT REPAIR.................................................................. 799 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 801 HOIST VALVE............................................................................. 801 Removal............................................................................. 801 Installation........................................................................ 801 O-Ring Replacement.................................................................. 802 INLET SECTION........................................................................... 803 Disassembly......................................................................... 803 Cleaning and Inspection............................................................. 804 Assembly............................................................................ 804 SPOOL SECTION........................................................................... 804 Disassembly......................................................................... 804 Cleaning and Inspection............................................................. 807 Assembly............................................................................ 807 HOIST PILOT VALVE....................................................................... 808 Removal............................................................................. 808 Installation........................................................................ 808 Disassembly......................................................................... 809 Cleaning and Inspection............................................................. 810 Assembly............................................................................ 811 BODY UP LIMIT SOLENOID.................................................................. 812 PILOT OPERATED CHECK VALVE.............................................................. 812 HOIST CYLINDERS......................................................................... 812 Removal............................................................................. 812 Installation........................................................................ 813 Disassembly......................................................................... 814 Cleaning and Inspection............................................................. 816 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 817 Quill Installation.................................................................. 817 Installation of Check Balls and Plugs in Quill...................................... 818 Assembly of Cylinder................................................................ 819 Assembly of Cylinder................................................................ 819 Pressure Testing.................................................................... 820 OVERCENTER MANIFOLD..................................................................... 821 HYDRAULIC CHECKOUT PROCEDURE.................................................................... 823 HYDRAULIC CHECKOUT PROCEDURE................................................................ 825 STEERING AND BRAKE PUMP................................................................. 825 Pressure Check And Adjustment Procedure............................................. 825 BLEEDDOWN MANIFOLD...................................................................... 827 SHOCK & SUCTION VALVES.................................................................. 827 Shock & Suction Valve Settings...................................................... 827 LEAKAGE TESTS........................................................................... 829 Steering Control Unit & Flow Amplifier.............................................. 829 Bleeddown Manifold.................................................................. 829 ACCUMULATOR BLEED DOWN PROCEDURE........................................................ 831 LOW STEERING PRESSURE SWITCH............................................................ 831 CHECKING HOIST SYSTEM PRESSURES......................................................... 838 Hoist System Relief Pressure Adjustment............................................. 838 Power Down Relief Pressure Adjustment............................................... 839 HOIST COUNTERBALANCE VALVE.......................................................... 840 Preparation:.................................................................... 840 Counterbalance Valve Pressure Check Only:....................................... 840 Counterbalance Valve Adjustment................................................. 841 HYDRAULIC SYSTEM FLUSHING PROCEDURE..................................................... 844 Hydraulic System Flushing Procedure................................................. 844 OIL CLEANLINESS CHECK............................................................... 849 SECTION M SPECIAL TOOLS ............................................................................ 851 HEATER OPTIONS ................................................................................. 853 GENERAL INFORMATION......................................................................... 855 TROUBLESHOOTING............................................................................. 855 HEATER ELEMENT.............................................................................. 855 Removal................................................................................. 855 Installation............................................................................ 856 GENERAL..................................................................................... 857 Maintenance............................................................................. 857 HEATING ELEMENT............................................................................. 857 Removal................................................................................. 857 Installation............................................................................ 858 THERMOSTAT.................................................................................. 858 Removal................................................................................. 858 Installation............................................................................ 858 GENERAL INFORMATION......................................................................... 859 TROUBLESHOOTING............................................................................. 859 HEATER ELEMENT.............................................................................. 859 Removal................................................................................. 859 Installation............................................................................ 860 SPECIAL TOOLS................................................................................... 861 NITROGEN CHARGING VALVE..................................................................... 861 ROLL-OUT ASSEMBLY........................................................................... 861 EYE BOLT.................................................................................... 861 OFFSET WRENCH............................................................................... 862 TORQUE ADAPTER.............................................................................. 862 HANDLE...................................................................................... 862 SEAL INSTALLER.............................................................................. 862 SLEEVE ALIGNMENT TOOLS...................................................................... 863 QUICK DISCONNECT COUPLING................................................................... 863 HARNESS..................................................................................... 863 SEAL INSTALLATION RING...................................................................... 863 BELT TENSION TESTER......................................................................... 864 BELT ALIGNMENT TOOL......................................................................... 864 SOCKETS AND ADAPTERS........................................................................ 864 DUST CAPS................................................................................... 864 HYDRAULIC SYSTEM FLUSHING TOOLS............................................................. 865 PAYLOAD DATA MANAGER........................................................................ 865 HYDRAULIC SYSTEM VACUUM PUMP................................................................ 865 MISCELLANEOUS SERVICE TOOLS................................................................. 866 BRAKE PISTON TOOL........................................................................... 867 HIGH VOLTAGE TOOLS.......................................................................... 870 2000 VDC METER.............................................................................. 870 GROUNDING STICKS............................................................................ 870 BODY PAD SPACER TOOL........................................................................ 871 RADIATOR SHUTTERS .............................................................................. 873 RADIATOR SHUTTERS........................................................................... 875 OPERATION............................................................................... 875 Hydraulic Circuit................................................................... 875 Electrical Circuit:................................................................. 876 MAINTENANCE AND REPAIR.................................................................. 876 TROUBLESHOOTING......................................................................... 877 Hydraulic Troubleshooting........................................................... 880 Electrical Troubleshooting.......................................................... 882 PAYLOAD METER III ™ ........................................................................... 883 OPERATION SECTION........................................................................... 887 Introduction............................................................................ 887 Data Summary........................................................................ 887 Data Gathering...................................................................... 887 COMPONENT DESCRIPTION................................................................... 888 System Diagram...................................................................... 888 Suspension Pressure Sensors......................................................... 888 Inclinometer........................................................................ 888 Operator Display.................................................................... 888 Operator Switch..................................................................... 889 Speed Input......................................................................... 889 Body-Up Switch...................................................................... 889 Brake Lock Switch................................................................... 889 Payload Meter....................................................................... 889 Communications Ports................................................................ 889 Key Switch Input.................................................................... 890 Payload Meter Power................................................................. 890 Load Lights......................................................................... 890 Wiring and Termination.............................................................. 891 TCI Outputs......................................................................... 891 OPERATOR’S DISPLAY AND SWITCH........................................................... 892 Reading the Speedometer............................................................. 892 Reading the Load Display............................................................ 892 Using the Operator ID............................................................... 892 Using the Load and Ton Counter...................................................... 892 Total Ton Counter................................................................... 892 Total Load Counter.................................................................. 893 Clearing the Counters............................................................... 893 Viewing Live Sensor Data............................................................ 893 Other Display Messages.............................................................. 893 PAYLOAD OPERATION & CALCULATION......................................................... 894 Description of Haul Cycle States.................................................... 894 Haul Cycle Description.............................................................. 894 Load Calculation.................................................................... 895 Carry Back.......................................................................... 895 Measurement Accuracy................................................................ 895 SOURCES FOR PAYLOAD ERROR............................................................... 895 Payload Error....................................................................... 895 Loading Conditions.................................................................. 896 Pressure Sensors.................................................................... 896 Swingloads.......................................................................... 896 Speed and Distance.................................................................. 896 HAUL CYCLE DATA......................................................................... 896 Haul Cycle Warning Flags............................................................ 898 Frame Torque Data................................................................... 899 Sprung Weight Data.................................................................. 899 Maximum Speed Data.................................................................. 899 Alarm Records....................................................................... 899 Fault Code Data..................................................................... 900 PC SOFTWARE OVERVIEW.................................................................... 901 System Configuration................................................................ 901 Installing the PLMIII Software...................................................... 901 DOWNLOADING DATA........................................................................ 902 PLM III SYSTEM CONFIGURATION............................................................ 903 Starting Communications............................................................. 903 Displayed Payload Units............................................................. 903 Time Units.......................................................................... 903 Connection Menu..................................................................... 903 Connecting to the Payload Meter..................................................... 904 Configure the Payload Meter......................................................... 904 Setting the Date and Time........................................................... 904 Setting the Truck Type.............................................................. 905 Setting the Gauge Display Units..................................................... 905 Setting the Frame Serial Number..................................................... 905 Setting the Truck Number............................................................ 905 Setting the Komatsu Distributor..................................................... 905 Setting the Komatsu Customer........................................................ 905 Clean Truck Tare.................................................................... 906 Inclinometer Calibration............................................................ 906 DATA ANALYSIS........................................................................... 907 Creating a Query.................................................................... 907 Sorting on Truck Unit Number........................................................ 907 Sorting on Truck Type............................................................... 907 Sorting on Date Range............................................................... 908 Sorting on Time Range............................................................... 908 Payload Detail Screen............................................................... 909 Creating Reports.................................................................... 909 Summary - one page report........................................................... 910 Detailed - multi-page report........................................................ 910 Creating Graphs..................................................................... 911 Exporting Data...................................................................... 911 CSV Export.......................................................................... 911 Compressed.......................................................................... 912 Importing Data...................................................................... 913 Deleting Haul Cycle Records......................................................... 913 Viewing Alarms...................................................................... 914 Deleting Alarm Records.............................................................. 914 TROUBLESHOOTING SECTION..................................................................... 915 TROUBLESHOOTING......................................................................... 915 Viewing Active Alarms............................................................... 915 Real-Time Data Display.............................................................. 915 Testing the Payload Lights.......................................................... 915 Creating Log Files of Inputs........................................................ 916 Daily Inspections................................................................... 916 Periodic Maintenance................................................................ 916 Abnormal Displays at Power-Up....................................................... 917 No Payload Display When Key Switch is Turned ON..................................... 918 No Display on Speedometer........................................................... 919 No Display on Operator Display...................................................... 919 No Communications With PC........................................................... 920 Load Lights Don’t Light During Loading.............................................. 921 Load Lights Remain ON............................................................... 922 Load Lights Remain ON During Dumping................................................ 922 Display Doesn't Clear When The Load Is Dumped....................................... 922 Calibration Problems................................................................ 923 Alarm 1 - Left Front Pressure High.................................................. 924 Alarm 2 - Left Front Pressure Low................................................... 924 Troubleshoot Wiring to Left Front Suspension........................................ 924 Alarm 3 - Right Front Pressure High................................................. 925 Alarm 4 - Right Front Pressure Low.................................................. 925 Troubleshoot Wiring to Right Front Suspension....................................... 925 Alarm 5 -Left Rear Pressure High.................................................... 926 Alarm 6 - Left Rear Pressure Low.................................................... 926 Troubleshoot Wiring to Left Rear Suspension......................................... 926 Alarm 7 - Right Rear Pressure High.................................................. 927 Alarm 8 - Right Rear Pressure Low................................................... 927 Troubleshoot Wiring to Right Rear Suspension........................................ 927 Alarm 9 - Inclinometer High......................................................... 928 Alarm 10 - Inclinometer Low......................................................... 928 Troubleshoot Inclinometer Wiring.................................................... 928 Alarm 13 - Body Up Input Failure.................................................... 929 Alarm 16 - Memory Write Failure..................................................... 930 Alarm 17 - Memory Read Failure...................................................... 930 Alarm 18............................................................................ 931 Alarm 19............................................................................ 931 Alarm 22............................................................................ 931 Operator Switch Doesn't Work........................................................ 932 Alarm 26 - User Switch Fault - SELECT............................................... 932 Alarm 27 - User Switch Fault - SET.................................................. 932 Connector Map....................................................................... 933 Connectors.......................................................................... 934 PLMIII CHECK OUT PROCEDURE.................................................................. 935 General Description..................................................................... 935 Tools Required.......................................................................... 935 Checkout Procedure...................................................................... 935 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................. 939 Flashburn Programming............................................................... 939 Confirmation Checklist.............................................................. 941 RESERVE ENGINE OIL SYSTEM ...................................................................... 943 RESERVE ENGINE OIL SYSTEM................................................................... 945 Operation............................................................................... 946 LED Monitor Light....................................................................... 946 Tank Fill Control (Optional)............................................................ 947 Filling Procedure (Remote Fill Feature)................................................. 947 SERVICE................................................................................. 948 Every 10 Hours, or once each shift:................................................. 948 Every 500 Hours..................................................................... 948 Changing Oil........................................................................ 948 TROUBLESHOOTING......................................................................... 949 Circuit Fuse........................................................................ 949 SYSTEM ELECTRICAL SCHEMATICS............................................................ 950 SECTION N OPERATOR CAB ............................................................................. 951 TRUCK CAB AND COMPONENTS........................................................................ 953 TRUCK CAB AND COMPONENTS.................................................................... 955 TRUCK CAB............................................................................... 955 Description......................................................................... 955 Removal............................................................................. 956 Installation........................................................................ 957 CAB DOOR................................................................................ 958 Removal............................................................................. 958 Installation........................................................................ 958 Door Adjustment..................................................................... 958 Door Jamb Bolt Adjustment........................................................... 959 Door Handle Plunger Adjustment...................................................... 960 Replace Door Glass.................................................................. 961 Replace Door Window Regulator....................................................... 965 Replacing the Door Handle or Latch Assembly......................................... 966 Replacing the Door and Door Hinge Seal.............................................. 966 Removing the Door Opening Seal...................................................... 967 Installation........................................................................ 967 GLASS REPLACEMENT....................................................................... 968 Adhesive-bonded Windows............................................................. 968 Replacement Procedure............................................................... 968 WINDSHIELD & REAR GLASS................................................................. 970 Removal............................................................................. 970 Installation........................................................................ 970 CAB COMPONENTS ................................................................................. 973 CAB COMPONENTS.............................................................................. 975 WINDSHIELD WIPERS....................................................................... 975 WIPER MOTOR......................................................................... 975 Removal......................................................................... 975 Installation.................................................................... 975 WIPER ARM........................................................................... 975 Removal......................................................................... 975 Installation.................................................................... 976 WIPER LINKAGE....................................................................... 976 Removal......................................................................... 976 Installation.................................................................... 976 WINDSHIELD WASHER....................................................................... 977 Operation........................................................................... 977 Service............................................................................. 977 OPERATOR SEAT........................................................................... 978 Seat Belts.......................................................................... 978 Adjustment.......................................................................... 978 Inspection.......................................................................... 979 Removal............................................................................. 979 Installation........................................................................ 979 PASSENGER SEAT.......................................................................... 980 Inspection.......................................................................... 980 Removal............................................................................. 980 Installation........................................................................ 980 OPERATOR COMFORT................................................................................ 981 OPERATOR COMFORT............................................................................ 983 HEATER / AIR CONDITIONER................................................................ 983 Operation........................................................................... 983 Fan Control Knob.................................................................... 983 Temperature Control Knob............................................................ 983 Directional Control Knob............................................................ 983 Heater Vents........................................................................ 983 COMPONENTS.............................................................................. 984 Circuit Breakers.................................................................... 984 Relays.............................................................................. 984 Heater Core......................................................................... 984 Fan Motor And Speed Control......................................................... 985 Actuators........................................................................... 985 Cab Air Filter...................................................................... 985 ENVIRONMENTAL IMPACT OF AIR CONDITIONING................................................ 988 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................... 988 PRINCIPLES OF REFRIGERATION............................................................. 988 Air Conditioning.................................................................... 988 Refrigeration - The Act Of Cooling.................................................. 989 The Refrigeration Cycle............................................................. 989 AIR CONDITIONER SYSTEM COMPONENTS....................................................... 990 Compressor (Refrigerant Pump)....................................................... 990 Service Valves...................................................................... 990 Condenser........................................................................... 990 Receiver-Drier...................................................................... 990 Expansion Block Valve............................................................... 991 Accumulator......................................................................... 991 Evaporator.......................................................................... 991 ELECTRICAL CIRCUIT...................................................................... 992 Thermostat.......................................................................... 992 Compressor Clutch................................................................... 992 Trinary™ Switch..................................................................... 993 SYSTEM SERVICING........................................................................ 994 SERVICE TOOLS AND EQUIPMENT............................................................. 995 Recovery/Recycle Station............................................................ 995 Leak Detector....................................................................... 995 Service Valves...................................................................... 996 Vacuum Pump......................................................................... 996 Manifold Gauge Set.................................................................. 997 Installing Manifold Gauge Set....................................................... 998 Purging Air From Service Hoses...................................................... 998 SYSTEM PERFORMANCE TEST................................................................. 999 SYSTEM OIL..............................................................................1000 Handling and Reusing PAG Oil........................................................1000 Oil Quantity........................................................................1000 Checking System Oil.................................................................1000 REFRIGERANT.............................................................................1001 Recycled Refrigerant................................................................1001 Reclaimed Refrigerant...............................................................1001 Refrigerant Quantity................................................................1001 R-134a Refrigerant Containers.......................................................1002 SYSTEM LEAK TESTING.....................................................................1002 Electronic Leak Detector............................................................1003 Tracer Dyes.........................................................................1003 Soap and Water......................................................................1003 RECOVERING AND RECYCLING THE REFRIGERANT................................................1003 Performing the Recovery Cycle.......................................................1003 Performing the Recycling Procedure..................................................1004 Evacuating and Charging the A/C System..............................................1004 SYSTEM REPAIR...........................................................................1004 System Flushing.....................................................................1005 A/C DRIVE BELT CHECKOUT PROCEDURE.......................................................1006 Pulley Alignment....................................................................1006 Belt Tension Check..................................................................1006 COMPONENT REPLACEMENT...................................................................1008 Hoses and Fittings..................................................................1008 Lines...............................................................................1008 Expansion Valve.....................................................................1008 Receiver-Drier......................................................................1008 Thermostat..........................................................................1008 Compressor..........................................................................1009 Accumulator.........................................................................1009 Clutch..............................................................................1009 Servicing the Compressor Clutch.....................................................1010 Pulley Removal......................................................................1012 Clutch Coil Check...................................................................1013 Pulley Installation.................................................................1013 Clutch Assembly Installation........................................................1013 EVACUATING THE SYSTEM...................................................................1015 CHARGING THE A/C SYSTEM.................................................................1017 TROUBLESHOOTING.........................................................................1018 Preliminary Checks..................................................................1018 Diagnosis Of Gauge Readings And System Performance..................................1018 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS..........................................1019 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..........................................1025 OPERATOR CAB CONTROLS...........................................................................1027 OPERATOR CAB AND CONTROLS...................................................................1029 STEERING WHEEL AND CONTROLS.............................................................1030 Horn Button.........................................................................1030 Tilt / Telescope Lever..............................................................1030 Multi-Function Turn Signal Switch...................................................1030 STEERING COLUMN.........................................................................1031 Removal.............................................................................1031 Steering Column Inspection..........................................................1031 Installation........................................................................1031 STEERING WHEEL..........................................................................1032 Removal.............................................................................1032 Installation........................................................................1032 PEDALS..................................................................................1034 Service Brake Pedal.................................................................1034 Dynamic Retarding...................................................................1034 Dynamic Retard Pedal................................................................1034 Throttle/Accelerator Pedal..........................................................1034 GRADE/SPEED RETARD CHART................................................................1035 OVERHEAD PANEL AND DISPLAYS.............................................................1036 CENTER CONSOLE..........................................................................1037 Directional Control Lever...........................................................1037 Override/Fault Reset Switch.........................................................1038 Engine Stop Switch..................................................................1038 L.H. Window Control Switch..........................................................1038 R.H. Window Control Switch..........................................................1038 Hoist Control Lever.................................................................1038 Raising The Dump Body...............................................................1038 Lowering The Dump Body..............................................................1038 Retard Speed Control (RSC) Adjust Dial..............................................1039 Retard Speed Control (RSC) Switch...................................................1039 Data Store Button...................................................................1040 KOMTRAX Plus Snapshot In Progress Light.............................................1040 Link Energized Light................................................................1040 Service Engine Light................................................................1040 DIAGNOSTIC PORTS....................................................................1040 KOMTRAX Plus Diagnostic Port........................................................1040 Interface Module (IM) Diagnostic Port...............................................1040 Payload Meter Diagnostic Port.......................................................1040 Truck Control Interface (TCI) Diagnostic Port.......................................1040 Propulsion System Controller (PSC) Diagnostic Port..................................1040 Engine Diagnostic Port (CENSE)......................................................1040 Engine Diagnostic Port (QUANTUM)....................................................1040 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.......................................1041 Fan Control Knob....................................................................1041 Temperature Control Knob............................................................1041 Directional Control Knob............................................................1041 Heater Vents........................................................................1041 INSTRUMENT PANEL........................................................................1042 Key Switch..........................................................................1044 Starting............................................................................1044 Rotating Beacon Light Switch (Optional).............................................1044 Heated Mirror Switch (Optional).....................................................1044 Rest Switch.........................................................................1044 Wheel Brake Lock Control............................................................1045 Hazard Warning Lights...............................................................1045 Cab/Air Conditioner Vents...........................................................1045 Engine Oil Pressure Gauge...........................................................1045 Right Turn Signal Indicator.........................................................1045 Tachometer..........................................................................1045 High Beam Indicator.................................................................1045 Speedometer/Payload Meter Display...................................................1046 Left Turn Signal Indicator..........................................................1046 Water Temperature Gauge.............................................................1046 Lamp Test Switch....................................................................1046 Light Switch........................................................................1046 Ladder Light Switch.................................................................1046 Manual Backup Switch................................................................1046 Fog Lights (Optional)...............................................................1047 Payload Meter Switch................................................................1047 Panel Light Dimmer..................................................................1047 Hydraulic Oil Temperature Gauge.....................................................1047 Hourmeter...........................................................................1047 Fuel Level Gauge....................................................................1047 OVERHEAD STATUS / WARNING INDICATORS....................................................1048 Status / Warning Indicator Light Symbols............................................1049 KOMTRAX Plus MONITORING SYSTEM..........................................................1055 Operation...........................................................................1055 Interface Module....................................................................1056 Basic Precautions...................................................................1056 SECTION P LUBRICATION AND SERVICE ..................................................................1057 LUBRICATION AND SERVICE.........................................................................1059 LUBRICATION AND SERVICE.....................................................................1061 GENERAL.................................................................................1061 830E SERVICE CAPACITIES.................................................................1061 HYDRAULIC TANK SERVICE..................................................................1061 Adding Oil..........................................................................1061 COOLING SYSTEM SERVICE..................................................................1062 Radiator Filling Procedure..........................................................1062 Coolant Specifications..............................................................1062 Unacceptable Practices..............................................................1062 WHEEL MOTOR SERVICE.....................................................................1062 RESERVE ENGINE OIL SYSTEM (Optional)....................................................1063 Reserve Oil Tank Filling Procedure (Remote fill)....................................1063 Inline Screen.......................................................................1063 QUICK FILL SERVICE CENTER...............................................................1064 LUBRICATION CHART.......................................................................1065 10 HOUR (DAILY) INSPECTION..............................................................1066 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................1069 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................1070 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1071 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1075 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS...........................................1077 2500 HOUR MAINTENANCE CHECKS............................................................1078 5000 HOUR MAINTENANCE CHECKS............................................................1078 AUTOMATIC LUBRICATION SYSTEM ...................................................................1079 AUTOMATIC LUBRICATION SYSTEM................................................................1081 GENERAL DESCRIPTION.....................................................................1081 SYSTEM COMPONENTS.......................................................................1083 Filter..............................................................................1083 Hydraulic Motor and Pump............................................................1083 Grease Reservoir....................................................................1083 Pressure Reducing Valve.............................................................1083 Flow Control Valve..................................................................1083 Solenoid Valve......................................................................1083 Vent Valve..........................................................................1083 Lubrication Cycle Timer.............................................................1083 Over Pressure Cut Off Switch........................................................1083 Grease Pressure Failure Switch......................................................1083 Injectors...........................................................................1083 Relief Valve........................................................................1083 SYSTEM OPERATION........................................................................1084 GENERAL INSTRUCTIONS....................................................................1085 Required Lubricant..................................................................1085 System Priming......................................................................1085 Filter Assembly.....................................................................1085 LUBRICANT PUMP..........................................................................1086 Pump Housing Oil Level..............................................................1086 Pump Pressure Control...............................................................1086 INJECTORS (SL-1 Series “H”).............................................................1086 Injector Specifications.............................................................1086 Injector Adjustment.................................................................1086 INJECTOR OPERATION......................................................................1088 PREVENTIVE MAINTENANCE PROCEDURES.......................................................1089 Daily Lubrication System Inspection.................................................1089 250 Hour Inspection.................................................................1089 1,000 Hour Inspection...............................................................1089 SYSTEM CHECKOUT.........................................................................1090 Lubrication Controller Check........................................................1090 Lubrication Controller Operation....................................................1090 Lubrication Controller Components...................................................1090 Lubrication Controller Adjustment...................................................1090 SYSTEM TROUBLESHOOTING CHART............................................................1092 SECTION Q ALPHABETICAL INDEX .......................................................................1095 SECTION R SYSTEM SCHEMATICS ........................................................................1099 HH360 HYDRAULIC SCHEMATIC ......................................................................1101 HH366 HYDRAULIC SCHEMATIC .....................................................................1102 HE484 ELECTRICAL SCHEMATIC HEATER/AC CONTROLS ..................................................1104 XS5100 ELECTRICAL SCHEMATIC ....................................................................1105
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