Page 1 CEBM013200 Shop Manual DUMP TRUCK A30708 - A30732 SERIAL NUMBERS ®...
Page 3 This manual should be kept in or near the machine for reference, and periodically reviewed by all personnel who will come into contact with it. This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written authorization from KAC.
Page 4 NOTES:...
Page 5: A00032 Introduction A
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.
Page 6 This “ALERT” symbol is used with the signal words, “DANGER”, “WARNING”, and “CAUTION” in this man- ual to alert the reader to hazards arising from improper operating and maintenance practices. “DANGER” identifies a specific potential hazard WHICH WILL RESULT IN EITHER INJURY OR DEATH if proper precautions are not taken.
Page 7 TABLE OF CONTENTS SUBJECT ................SECTION GENERAL INFORMATION .
Page 8 KOMATSU MODEL 830E TRUCK Introduction A00032...
Page 9 ! " #$% &...
Page 10 #$% & ! "...
Page 11 ENGINE vibration. The tinted safety-glass windshield and side windows provide excellent visibility. The seat is a This Model 830E Truck is powered by a Komatsu comfortable, adjustable suspension seat, the steer- SDA16V160 diesel engine rated at 2500 hp (1864 ing wheel provides tilt and telescoping adjustments kW) @ 1900 RPM.
Page 12 830E MAJOR COMPONENTS A2-2 Major Component Description A02063...
Page 13 SPECIFICATIONS These specifications are for the standard Komatsu 830E Truck. Customer Options may change this list- ing. 24 VDC ELECTRIC SYSTEM ENGINE Batteries . . Four 12 Volt Batteries in Series/Parallel Komatsu SDA16V160 . . . 220 Ampere-Hour Capacity w/Disconnect Switch (Optional SSDA16V160) Alternator .
Page 14 *Not To Exceed 850,000 lbs. (385 553 kg) including ...Spring Applied, Hydraulically Released options, liners, fuel and payload, and subject to approval by Komatsu. DUMP BODY CAPACITIES AND DIMENSIONS Standard, Heaped @ 2:1 (SAE) . . 193 yd (147 m Struck .
Page 15 UNAUTHORIZED MODIFICATION • Any modification made to this vehicle without authorization from Komatsu can possibly create hazards. • Before making any modification, consult the authorized regional Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification.
Page 16 LEAVING THE OPERATOR'S SEAT • When preparing to leave the operator's seat, do not touch any control lever that is not locked. To prevent accidental operations from occurring, always carry out the following: • Move the shift control lever to Neutral (N) and set the parking lever/switch to the PARKING position. •...
Page 17 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES • Immediately after operations, the engine cooling water, engine oil, and hydraulic oil are at high temperature and are under pressure. If the cap is removed, or the oil or water is drained, or the filters are replaced, there is danger of serious burns.
Page 18 The ROPS installed on equipment manufactured and designed by Komatsu America Corp. fulfills all of the regulations and standards for all countries, but if it is modified or repaired without authorization from Komatsu America Corp., or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its function properly.
Page 19 In addition, know the proper use and care of all the safety equipment on the truck. Only qualified operators or technicians should attempt to operate or maintain the Komatsu Truck. Safe practices start before the operator gets to the equipment! SAFETY AT WORKSITE •...
Page 20 IN OPERATOR'S CAB - BEFORE STARTING ENGINE • Do not leave tools or spare parts lying around in the operator's compartment or allow trash to accumulate in cab of truck. Keep all unauthorized reading material out of truck cab. • Keep the cab floor, controls, steps, and handrails free of oil, grease, snow, and excess dirt.
Page 21 • Report immediately to supervisor any conditions on haul road, pit or dump area that may cause an operating hazard. • Check for flat tires periodically during shift. If truck has been run on a “flat”, it must not be parked in a building until the tire cools.
Page 22 TRAVELING ON SLOPES • Traveling on slopes could result in the machine tipping over or slipping. • Do not change direction on slopes. To ensure safety, go down to level ground before turning. • Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine slip on even the slightest slope.
Page 23 WHEN DUMPING • Before starting the dumping operation, check that there is no person or object behind the machine. • Stop the machine in the correct position, and check again that there is no person or object behind the machine. Give the determined signal, then slowly operate the dump body.
Page 24 BATTERY BATTERY HAZARD PREVENTION • Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. • Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once.
Page 25 ALWAYS attach the WARNING TAG to the control lever in the operator's cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary. • These tags are available from your Komatsu distributor. • Part No. 09963-03000 PROPER TOOLS •...
Page 26 DURING MAINTENANCE PERSONNEL • Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and using a sledge-hammer. ATTACHMENTS • Place attachments that have been removed from the machine in a safe place so that they do not fall.
Page 27 RADIATOR WATER LEVEL • If it is necessary to add water to the radiator, stop the engine and allow the engine and radiator to cool down before adding the water. • Slowly loosen the cap to relieve pressure before removing the cap. USE OF LIGHTING When checking fuel, oil, coolant, or battery electrolyte, always use lighting with anti-explosion specifications.
Page 28 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE • Immediately after stopping operations, the engine cooling water and oil at all parts are at high temperature and under high pressure.In this condition, if the cap is removed, or the oil or water are drained, or the filters are replaced, it may result in burns or other injury.
Page 29 If the proper procedure for carrying out maintenance or replacement of the wheel or tire is not used, the wheel or tire may burst and cause serious injury or damage. When carrying out such maintenance, please consult the authorized regional Komatsu America Corp. distributor, or the tire manufacturer. STORING TIRES AFTER REMOVAL •...
Page 30 ADDITIONAL JOB SITE RULES • Use this space to add any ADDITIONAL Job Site Rules not covered in any of the previous discussions. • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ •...
Page 31 1. Only qualified maintenance personnel who understand the systems being repaired should accomplish repairs. 2. Many components on the Komatsu Truck are large and heavy. Insure that lifting equipment - hoists, slings, chains, lifting eyes - are of adequate capacity to handle the lift.
Page 32 NOTES: A3-18 General Safety and Operating Instructions A03020...
Page 33 Empty the dust pans on the left side air cleaner truck. Only qualified operators or technicians should assemblies. attempt to operate or maintain the Komatsu Truck. 2. Move behind the front of the left front tire, Safe practices start before the operator gets to...
Page 34 A3-20 General Safety and Operating Instructions A03020...
Page 35 9. Move on around the hydraulic tank and in front 16. Move on around the right dual tires, inspect of the rear dual tires, inspect the hoist cylinder between the tires for rocks, and for condition of for any damage and leaks, also that lower the rock ejector, inspect the tires for cuts or guard is in place.
Page 36 26. Climb ladder to main deck. Always use grab rails 34. Read and understand the description of all Oper- and ladder when mounting or dismounting from ator Controls in Section "N", Cab, "Instrument the truck. Clean ladder and hand rails of any Panel and Indicator Switches".
Page 37 3. Operate each of the truck's brake circuits at NOTE: If the truck is equipped with a Komatsu least twice prior to operating and moving the engine, a time delay will occur before starter truck. These circuits include individual activa- engagement and engine cranking begins.
Page 38 MACHINE OPERATION SAFETY PRE- CAUTIONS After the truck engine is started and all systems are functioning properly, the operator must follow all local Do not use "Brake Lock" or "Emergency Brake" safety rules to insure safe machine operation. (if equipped) for parking. With engine stopped, hydraulic pressure will bleed down, allowing brakes to release! 8.
Page 39 7. Do not stop or park on a haul road unless Dynamic Retarding is available in "Forward/Reverse" unavoidable. If you must stop, move truck to a at all truck speeds above 0 mph/kph; however, as the safe place, apply parking brake, and shut down truck speed slows below 3 mph (4.8 kph), the avail- engine before leaving cab.
Page 40 STARTING ON A GRADE WITH A 5. When being loaded, operator should stay in truck cab with engine running. Place Selector LOADED TRUCK Switch in "Neutral" and apply Wheel Brake Initial propulsion with a loaded truck should begin Lock. from a level surface whenever possible, but when 6.
Page 41 4. Pull the lever to NOTE: DO NOT drive forward if the tail of body will the rear to actu- not clear the crusher wall in the fully raised position. ate hoist circuit. b. Shift Selector Switch to "Forward", release (Releasing the Brake Lock, depress Override button and lever...
Page 42 TOWING c. Move hoist lever back to the "hoist" position to fully raise the dump body. Then release Prior to towing a truck, many factors must be care- the hoist lever so it returns to the "hold" posi- fully considered. Serious personal injury and/or sig- tion.
Page 43 NORMAL ENGINE SHUTDOWN DELAYED ENGINE SHUTDOWN PROCEDURE PROCEDURE 1. Stop the truck out of the way of other traffic on a The following procedure should be followed at each level surface and free of overhead power lines engine shutdown. or other obstructions (in case dump body 1.
Page 44 SUDDEN LOSS OF ENGINE POWER RESERVE ENGINE OIL SYSTEM (Optional) NOTE: If the engine suddenly stops, there is enough hydraulic pressure stored in the brake and steering The reserve oil tank for the engine is designed to add accumulators to allow the operation of the steering more oil capacity to the engine and to make less fre- and brake functions.
Page 45 Changing Oil Drain both the engine sump and the reserve tank. Refill both engine and reserve tank with new oil to proper levels. Change engine and reserve tank filters as required. Start engine and check for proper operation. NOTE: Do not use the oil in the reserve tank to fill the engine sump.
Page 46 NOTES: A3-32 General Safety and Operating Instructions A03020...
Page 47 WARNINGS AND CAUTIONS The following pages give an explanation of the Warning, Caution, and Service Instruction plates and decals attached to the truck. The plates and decals listed here are typical of this model, but because of customer options, individual trucks may have plates and decals that are different from those shown here. The plates and decals must be kept clean and legible.
Page 48 A warning instruction is applied below the Parking Brake and the Rear Wheel Brake Lock switches, which are located to the right of the steering column on the instrument panel. Pushing the top of the rocker-style switch turns the function ON, pushing the bottom, turns it OFF. The Parking Brake is spring applied and hydraulically released.
Page 49 A warning plate is mounted on top of the radiator surge tank cover near the radiator cap.The engine cooling system is pressurized. Always turn the engine off and allow the engine to cool before removing radiator cap. Unless the pressure is first released, removing the radiator cap after the engine has been running for a time will result in the hot cool- ant being expelled from the radiator.
Page 50 A decal plate is located on the frame near the left hoist cylinder which provides the operator or techni- cian with the hook-up procedure for dumping a loaded, disabled truck, by using a functional truck for hydraulic power. Refer to the Service manual for additional instruc- tions for using this procedure.
Page 51 (It is not necessary to disconnect or remove any control circuit cards on electric drive Komatsu Trucks or any of the "AID" circuit control cards.) Always fasten the welding machine ground (-) lead to the piece being welded;...
Page 52 Warning and Danger plates are located inside the door of the brake system cabinet behind the cab. This DANGER plate alerts technicians to read the warning labels attached to the side of each of the accumulators prior to releasing internal nitrogen pressure or disconnecting any hydraulic lines or hardware.
Page 53 The CL is used to verify the accuracy of the individual PIN. FC - Character positions 10 and 11 identify the Factory Code (FC). The FC identifies the Komatsu factory in charge of claims for the product. The FC for electric drive trucks is 61.
Page 54 The Lubrication Chart is located on the right hand side of the radiator grille and is for reference. Refer to the "Lubrication Section" in this manual for more complete lubrication instructions. A4-8 Warnings and Cautions A04046...
Page 55: Table Of Contents
“Standard Torque” values listed below in Table I (and TABLE III . . Standard Metric Assembly Torque . . A5-2 in Komatsu shop manuals), excessive stress and pos- TABLE IV..JIC Swivel Nuts Torque Chart . . A5-3 sible breakage of the fasteners may result.
Page 56 * NOTE: This list represents the current Engineer- ing approved sources for use in Komatsu manufac- ture. It is not exclusive. Other products may meet the same specifications of this list.
Page 57 TABLE IV. TABLE VI. TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR WITH OR WITHOUT O-RING SEALS O-RING BOSS FITTINGS SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE CODE (O.D.) UNF-2B FT. LBS. CODE (O.D.) UNF-2B FT.
Page 58: Table V
TABLE VIII. TORQUE CONVERSIONS Foot Pounds – ft. lbs. To Newton-meters (N.m) FT. LBS. (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96...
Page 59: Table Xi
TABLE XI. PRESSURE CONVERSIONS Pounds/square inch (psi) To Megapascals (MPa) Formula: psi x 0.0069 = MPa (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31 1.38 1.45 1.52 1.59 1.65 1.72 1.79...
Page 60 TABLE XIII COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS ENGLISH To METRIC METRIC To ENGLISH Multiply Multiply To Convert From To Convert From inch – in. millimeter (mm) 25.40 millimeter (mm) inch – in. 0.0394 inch – in. centimeter (cm) 2.54 centimeter (cm)
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Page 81 SECTION B STRUCTURES INDEX STRUCTURAL COMPONENTS ........B2 Ladders .
Page 82 NOTES B1-2 Index B01018...
Page 83: Structural Components
STRUCTURAL COMPONENTS LADDERS A diagonally mounted ladder (7, Figure 2-1) pro- The diagonal ladder must be removed from the vides an easy and safe path for the operator to truck if it becomes necessary to remove the radiator mount and dismount the truck. In addition, a vertical or the complete power module for major repairs.
Page 84: Right Hand Deck
Removal 1. Remove handrails (8, Figure 2-1) attached to diagonal ladder handrail and the platform. 2. Attach a lifting device to ladder structure (7). 3. Remove all attaching hardware and lift diagonal ladder from mounts. 4. If vertical ladder removal is necessary, attach a lifting device to ladder structure (6).
Page 85: Center And Left Hand Deck Components
CENTER AND LEFT HAND DECK COMPONENTS The center deck and left hand deck utilize several individual structures mounted on the main deck sup- ports. Refer to Figure 2-1 for the location of individual Before performing deck removal or repairs, be sections.
Page 86: Fuel Tank
FUEL TANK Installation Removal 1. Lower tank into position over upper mounting 1. Raise truck body and install body safety cables. brackets. 2. Drain sediment from tank and dispose of prop- 2. Install caps, lockwashers, and capscrews at erly. Drain remainder of fuel into clean contain- upper mounting trunnions (1, Figure 2-3) and ers.
Page 87: Dump Body
12. Body Pivot Bushing approximately 2X the weight being lifted. When in doubt as to the weight of components or any assembly procedure, contact the Komatsu area representative for further information. 6. Remove body pivot pins (6) far enough to allow spacer (9) to drop out.
Page 88: Installation
407 N.m (300 ft. lbs.) torque. Be sure locknuts are in good condition. When in doubt as to the weight of components or any assembly procedure, contact the Komatsu 8. Install mud flaps, rock ejectors, electrical cables area representative for further information.
Page 89: Body Pads
BODY PADS 2. Remove hardware attaching pads to the dump It is not necessary to remove the dump body to replace body. (Refer to Figure 3-4) body pads. Pads should be inspected during sched- uled maintenance inspections and replaced if worn 3.
Page 90: Adjustment
Adjustment BODY GUIDE 1. Vehicle must be parked on a flat, level surface for 1. Body guide wear points should be inspected each inspection. time a body pad inspection is performed. (Refer to Figure 3-5.) The body guide should be centered 2.
Page 91: Body Position Indicator
3. Secure the cable clevis pins with cotter pins. 4. After maintenance work is completed, reverse the above procedure to remove cable assembly and place it in the storage position. BODY POSITION INDICATOR The Body Position Indicator is a device mounted on the canopy of the dump body.
Page 92 NOTES: B3-6 Dump Body B03018...
Page 93 SECTION C ENGINE INDEX POWER MODULE..............C2-1 Preparation .
Page 94 NOTES C1-2 Index C01024...
Page 95: Power Module
POWER MODULE The radiator, engine and alternator/blower assemblies Removal are mounted on a roller equipped subframe which is 1. Disconnect batteries using the following proce- contained within the truck's main frame and is referred dure in this order: to as a “Power Module”. This arrangement permits a.
Page 96 9. Close both cab heater shutoff water valves dis- connect water lines and drain water from the heater core. Secure water lines away from engine compartment so as not to interfere with power module removal. 10. Remove capscrews (2, Figure 2-2) and nuts secur- ing left (1) and right (3) exhaust ducts to turbo- charger outlets.
Page 97 Note: Illustration shows engine equipped with two-stage turbo- chargers. Single stage turbo- charger equipped engine ducts and supports are similar. FIGURE 2-3. AIR INTAKE DUCTS 1. Hump Hose 4. Turbocharger 7. T-Bolt Clamp 2. Support Rods 5. Center Deck Str. 8.
Page 98 FIGURE 2-4. ENGINE MODULE INSTALLATION 1. Pump Driveshaft 6. Rear Subframe Mount Bracket 11. Grille Str. 2. Rear Module Lift Eye 7. Module Subframe 12. Upper Radiator Support Rod 3. Cap 8. Front Module Lift Eye 13. Engine 4. Capscrews 9.
Page 99: Installation
FIGURE 2-6. POWER MODULE LIFT POINTS 1. Module Lifting Tool 4. Engine 2. Main Alternator 5. Power Module Sub- 3. Module Lift Points frame 21. Raise the power module slightly to determine if module is on an even plane. Move the power module straight out of truck to a clean work area FIGURE 2-5.
Page 100 6. Lower the power module to the subframe guide 21. Connect the hydraulic pump drive shaft (1, Figure rails, relax the hoist slightly and roll the power 2-4) to the companion flange on the alternator. module into truck frame until lifting chains contact Tighten capscrews to standard torque.
Page 101: Cooling System
COOLING SYSTEM COOLING SYSTEM DESCRIPTION A second, “high temperature” core (3), located at The standard 830E engine is a Komatsu model the rear of the radiator assembly is used for the SDA16V1610 single stage turbocharged engine engine coolant circuit. In this circuit, the engine equipped with aftercoolers.
Page 102: Radiator
RADIATOR Removal 1. Place battery disconnect switch in the “OFF” position. 2. Release pressure from cooling system and drain coolant. 3. Remove cover (7, Figure 3-2) protecting surge tank (1). FIGURE 3-3. RADIATOR PIPING AND MOUNTS (Viewed from Below) 1. Radiator Assembly 3.
Page 103 FIGURE 3-4. RADIATOR AND SHROUD (Rear View) 1. Shroud 5. Hose 9. Level Sensor 2. Fan Guard Str. 6. Lift Points 10. Receiver/Drier 3. Support Rod 7. Upper Tubes 11. Pressure Switch 4. Clamp 8. Vent Hoses c. Disconnect headlight wire harness at each 9.
Page 104: Installation
Service receiver/drier (10) hoses. Connect pressure switch (11). Radiator service is a specialized function usually not 12. Install surge tank hoses and electrical wiring to accomplished by most maintenance shops. The the coolant level probe (9, Figure 3-4). Clamp large size and weight of the off-road truck radiators hoses and electrical cables to the shroud.
Page 105: Power Train
POWER TRAIN ALTERNATOR REMOVAL PROCEDURE Removal (Komatsu SSDA16V160 or SDA16V160 Engine) The following instructions cover the removal of the main alternator from the engine after the power module has been removed from the truck. (Refer to Figure 4-2.) When lifting alternator, attach hoist to lift eyes only.
Page 106 3. Remove access covers at front, right side of the engine flywheel housing. Install engine barring tool as shown in Figure 4-3. FIGURE 4-3. ACCESS TO ALTERNATOR/ ENGINE DRIVE RING CAPSCREWS 1. Engine Barring Tool 3. Flywheel Housing 2. Access Hole 4.
Page 107: Engine/Alternator Mating
“Measurement C”:_________________________ (CW), or counterclockwise (CCW), is the direc- tion of rotation when looking at the front (damper end) of engine. • Crankshaft end-play for Komatsu SSDA16V160 or SDA16V160 Engine: 0.005 - 0.015 in. (0.13 - 0.38 mm). SERVICE DATA - Eccentricity & Runout Limits Description T.I.R.
Page 108 4. Refer to Figure 4-6. Alternator End-play: a. Using a flat steel bar (3, Figure 4-6) bolted rigidly to the alternator rotor (2), install a 5/8" - 11 capscrew (4) at each end into the alter- nator housing (1). Leave capscrews finger- tight.
Page 109 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine When lifting alternator, attach hoist to lift eyes only. The alternator weighs approximately 7,700 lbs. (3493 kg). Use a lifting device that can handle the load safely. 1. Use the two top lift brackets provided on the alternator for lifting.
Page 110: Engine
ENGINE 4. Lift engine from subframe and move to clean work area for further disassembly. Removal Service Refer to instructions in previous sections for Complete instructions covering the disassembly, removal instructions for the Power Module, alterna- assembly and maintenance of the engine and its tor, and radiator assembly.
Page 111: Air Filtration System
AIR FILTRATION SYSTEM AIR CLEANER Operation 2. Check filter restriction gauges, during operation. Intake air, required by the diesel engine and by the The filters should be cleaned or replaced when the truck air system, passes through the air cleaner assem- gauges read between 20 and 25 inches H O vac- blies mounted on each side of the radiator.
Page 112: Safety Filter Element
91186 Safety Element Indicator 90109 FIGURE 5-2. AIR CLEANER ASSEMBLY Installation Removal 1. Dust Cap 5. Wing Nut 9. Safety Filter Element 12. Clean Air Outlet 2. Dust Cap Gasket 6. Wing Nut Gasket 10. Main Filter Element 13. Pre-Cleaner Gasket 3.
Page 113: Air Intake Troubleshooting
Installation c. Dry the element thoroughly. If drying is done with heated air, the maximum temperature 1. Reset the indicator nut from red to green by gently must not exceed 140°F (60°C) and must be blowing air through threaded hole from gasket circulated continually.
Page 114: Precleaner Section Cleaning
FIGURE 5-4. CLEANING FILTER ELEMENT WITH COMPRESSED AIR 90112 Precleaner Section Cleaning FIGURE 5-5. REMOVING DUST FROM TUBES The tubes in precleaner section of air cleaner assembly should be cleaned at least once annually and at each engine overhaul. More frequent cleaning may be nec- 3.
Page 115 5. Submerge precleaner section (see Figure 5-6.) in 7. Check precleaner gaskets (13) carefully for any a solution of Donaldson D-1400 and warm water evidence of air leaks, replace if necessary (mix solution according to package directions). 8. Install precleaner section, with serviceable gas- Soak for 30 minutes, remove from solution and kets, on air cleaner assembly and install all mount- rinse thoroughly with fresh water and blow dry.
Page 116 NOTES C5-6 Air Filtration System C05012 4/98...
Page 117 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 24VDC ELECTRIC SUPPLY SYSTEM ..........D2-1 Electrical System Description .
Page 118 • Electric shock can cause serious or fatal injury. Only qualified electrical mainte- nance personnel should perform electrical testing • This system is capable of causing physical harm. Use caution during test proce- dures to protect personnel from injury. • All potential testing should be considered hazardous.
Page 119: 24Vdc Electric Supply System
24VDC ELECTRIC SUPPLY SYSTEM ELECTRICAL SYSTEM DESCRIPTION Excessive consumption of water indicates leakage or overcharging. Normal water usage for a unit operat- The truck utilizes a 24VDC electrical system which ing eight hours per day is about one to two ounces supplies power for all non-propulsion electrical com- per cell per month.
Page 120 NOTE: When washing batteries, make sure cell caps The rate of self-discharge of a battery kept at 100° F are tight to prevent cleaning solution from entering (38°C) is about six times that of a battery kept at the cells. 50°F (19°...
Page 121: Battery Charging System (Niehoff)
BATTERY CHARGING SYSTEM (Niehoff) TROUBLESHOOTING PROCEDURES (On-Truck) General Description Most 24 volt charging system problems can be diag- The Niehoff alternator (Figure 2-1) is a heavy duty, nosed with the alternator installed on the truck, 24 VDC unit rated at 240 amps. A solid state voltage operating under normal conditions.
Page 122 Preliminary Checks Test Procedure 1. Check the drive belt tension. Refer to engine 1. Start engine, accelerate to high idle and manufacturer’s Operation and Maintenance observe meters. Manual for belt tension requirements. 2. Insure that an undercharged battery condition has not been caused by accessories having been left ON for extended periods.
Page 123 • If grounding the harness male pin has no effect, the alternator is defective and should be replaced. FIGURE 2-3. REGULATOR BYPASS TEST 1. Alternator Control Unit 2. “R” Terminal (Relay) 3. “E” Terminal (Energize) FIGURE 2-2. TEST METER HOOKUP 4.
Page 124 ON VEHICLE TROUBLESHOOTING GUIDE - SELF ENERGIZED ALTERNATOR ALTERNATOR ELECTRICAL CONDITION - Low Voltage - High Voltage - No Voltage PRELIMINARY PROCEDURES NO VOLTAGE OUTPUT Causes of no voltage output: Common problems, all applications: • No drive belt. Check alternator drive belt (s). •...
Page 125 Maintenance Free types: Medium amps are defined as some multiple of the low amp value, perhaps 30 amps for the Group-8D • Immediately after engine start, system volts are and 10-15 amps for the Group-31. This rate of lower than regulator setpoint with low amps. amperage will cause a rise in battery temperature •...
Page 126: Advanced System Troubleshooting
ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized NO ALTERNATOR OUTPUT GO TO “R” TERMINAL ON ALTERNATOR With engine running, measure value of AC STATIC TEST - ENGINE OFF, KEY ON, BATTERY voltage from “R” terminal to “Ground”. SWITCH ON. • If no AC volts are present, alternator is not Identify and locate “B+”, “E”, and “R”...
Page 127 FIGURE 2-4. ALTERNATOR TERMINALS 1. Control Unit 2. “R” Terminal 3. Link Strap 4. “E” Terminal 5. “B+” Terminal 6. Ground Terminal GO TO REGULATOR (IF REQUIRED) • If meter shows battery voltage, circuit is good. Continue test. Disconnect voltage regulator from alternator. There Insert “+”...
Page 128: Operation
OPERATION (WITH PRELUBE) (Refer to electrical schematic diagram, Figure 2-5.) The Komatsu SSDA16V160 engine includes an The prelube system is activated when the operator engine pre-lubrication system designed to reduce turns the key switch and holds it in the “start” posi- wear due to dry starts.
Page 129: Maintenance
MAINTENANCE Pressure Switch The pressure switch (2, Figure 2-5) is a 2.5 psi (17.2 Prelube system maintenance should be performed kPa), normally closed (N.C.) switch, located so that it annually or at 5000 hour intervals as described can sense oil pressure after the engine oil has below.
Page 130 Troubleshooting Prelube Starter Circuit Two distinct phases are involved in a complete prelubrication cycle. The two phases are: 1. Prelubrication Phase- Begins when the key switch is held in the START position. A circuit is provided to ground through the normally closed pressure switch. The circuit is interrupted upon opening of the pressure switch when the prelube pressure reaches 2.5 psi (17.2 kPa).
Page 131 Problem Probable Cause • Starter has very long prelubrication cycle. Except for severe cold weather starts, the prelube cycle should not exceed 45 seconds. a. Low oil pressure. b. Make sure oil of the proper viscosity is being used in respect to outside temperature. (Refer to engine manufacturer's specifications).
Page 132 Note: When a Komatsu SSDA16V160 engine with a prelube system is installed, there is a delay between the time the key switch is moved to the START position, and the starter motors actuate.
Page 133: Troubleshooting
CRANKING MOTOR TROUBLESHOOTING If the cranking system is not functioning properly, check the following to determine which part of the system is at fault: Batteries -- Verify the condition of the batteries, cables, connections and charging circuit. Wiring -- Inspect all wiring for damage or loose connections at the keyswitch, magnetic switches, solenoids and cranking motor(s).
Page 134 3. Failure to operate with high current draw indi- cates: FIGURE 2-8. CRANKING MOTOR ASSEMBLY a. A direct ground in the terminal or fields. 1. C.E. Frame 51. O-ring b. “Frozen” bearings (this should have been 2. Washers 52. Inspection Plug determined by turning the armature by 3.
Page 135 FIGURE 2-8 CRANKING MOTOR ASSEMBLY D02023 24 VDC Electric Supply System D2-17...
Page 136 Cleaning and Inspection 2. Short circuits in the armature are located by use of a growler. When the armature is revolved in 1. The drive (71), armature (45) and fields (46) the growler with a steel strip such as a hacksaw should not be cleaned in any degreasing tank, blade held above it, the blade will vibrate above or with grease dissolving solvents, since these...
Page 137 5. To check for grounds, move battery lead from “G” (Figure 2-10) and from “MTR” (Figure 2-11) to the solenoid case. Ammeter should read zero. If not, the winding is grounded. FIGURE 2-9. SIMPLIFIED SOLENOID CIRCUIT Solenoid Checks A basic solenoid circuit is shown in Figure 2-9. Sole- noids can be checked electrically using the following procedure.
Page 138 Assembly Lubricate all bearings, wicks and oil reservoirs with SAE No. 20 oil during assembly. Bearing Replacement: 1. If any of the bronze bearings are to be replaced, dip each bearing in SAE No. 20 oil before pressing into place. 2.
Page 139 MAGNETIC SWITCH The magnetic switch is a sealed unit and not repair- able. FIGURE 2-13. CHECKING PINION CLEARANCE FIGURE 2-14. MAGNETIC SWITCH ASSEMBLY Pinion Clearance Removal 1. Remove battery power as described in Cranking To adjust pinion clearance, follow the steps listed Motor “Removal”.
Page 140 Coil Test 1. Using an ohmmeter, measure the coil resis- tance across the coil terminals. a. The coil should read approximately 28Ω at 72°F (22.2° C). ∞ b. If the ohmmeter reads , the coil is open and the switch must be replaced. c.
Page 141: 24Vdc Electrical System Components
24 VDC ELECTRICAL SYSTEM COMPONENTS PASSENGER SEAT BASE LUBRICATION SYSTEM TIMER COMPARTMENT Automatic Lubrication System lubrication interval is controlled by the timer (17, Figure 3-1). Lubrication The 24 VDC electrical system components shown in cycle frequency can be adjusted by removing the Figure 3-1 are accessed by unlatching the passenger timer cover and selecting one of five different timing seat base lid and tilting the passenger seat forward.
Page 142 FIGURE 3-1. PASSENGER SEAT BASE COMPARTMENT 1. Seat Base 9. Hoist Control 18. Data Store Switch 2. Tail Light Resistor/Diodes 10. Compartment Service Light 19. QUANTUM Diagnostic Port (RD1/RD2) 11. Brake Warning Buzzer (BWB) (Engine) 3. Terminal Board (TB13) 12. 5 Minute Idle Relay 20.
Page 143 (This is a momentary switch that also latches the 5 Section “E” for additional information. minute idle timer in the energized position.) When the KOMATSU ENGINE QUANTUM CONNECTOR timer is energized, internal contacts close and ener- gize the relay and contactor described below.
Page 144: Alarm Indicating Device (Aid) System
ALARM INDICATING DEVICE (AID) SYSTEM lamps are fed by circuits 12FD (flashing) and 12MD (steady). The Alarm Indicating Device (16) is connected to the electrical accessories circuits to provide the operator When an indicator circuit is not activated, there is no with a warning indication of a malfunction.
Page 145 Hot Switch Inverter NOTE: Some electronic engine controls monitor coolant temperature. If the engine controls monitor The Hot Switch Inverter Card in slot 3 (3, Figure 3-2) the circuit, a 2K Ω resistor is installed to replace the is used to operate and test the service brake indica- temperature sensor and disable the AID system tor light.
Page 146: Battery Equalizer Box
BATTERY EQUALIZER BOX Most truck control and accessory circuits operate at 24VDC. However, a 12VDC Power Source is avail- able for the cigar lighter socket, power window motors, and AM/FM, communications and dispatch radios. For this purpose, a battery equalizer system is uti- lized to obtain the required 12VDC and insure that the two pairs of 12 volt, series wired batteries are charged and discharged equally.
Page 147: Body Up Switch
BODY-UP SWITCH HOIST LIMIT SWITCH The body-up switch is designed to prevent propul- The hoist limit switch actuates a solenoid in the hoist sion in “Reverse” with the dump body raised. This circuit to stop the hoist cylinders short of full exten- switch also prevents forward propulsion unless the sion and prevent possible damage to the dump body override button is depressed and held.
Page 148: Volt Relay And Diode Boards
24 VOLT RELAY AND DIODE BOARDS RELAY BOARDS The truck is equipped with 5 relay boards and a Description diode board to provide control in many of the 24 volt Each relay board is equipped with four green lights electrical system circuits. Some trucks may have a (9, Figure 3-6) and one red light (7).
Page 149: Circuit Breaker Chart
SERVICE To replace a circuit breaker: NOTE: Always replace a circuit breaker with one of To replace a relay: the same amperage capacity as the one being 1. Remove one screw (10, Figure 3-6) holding the removed. crossbar in place and loosen the other screw. 1.
Page 150 4. Remove nuts and star washer from back side of RELAY BOARD COMPONENTS circuit board that holds the breaker in place. Relay Board 1 ....Turn Signal 5.
Page 151 Relay Board 5 ....Head Lights Relay Board 3....Stop Lights 1 - Light Display Module card 1 - Light Module Display card 1 - Lights Control Light (Green): This light is “ON”...
Page 152 Relay Board 6 ....Auxiliary Panel If the Auxiliary Panel, Relay Board 6 is installed, additional circuits may be added by utilizing the empty relay terminals provided. (Refer to Figure 3-7.) To add an additional circuit with a relay, connect the wires as described below: The coil circuit for the relay is the “+”...
Page 153 DIODE BOARD 1 The truck is equipped with a diode board (1, Figure 3-8) containing replaceable diodes (4). Some of the diodes are used in the coil circuit of various relays to suppress the resultant coil voltage spike when power is removed from the circuit, preventing damage to other circuit components (lamp filaments etc.).
Page 154 TABLE I. CIRCUIT BREAKERS AMPS DEVICE(S) PROTECTED LOCATION CB13 Turn Signal & Clearance Lights RB1, Control Cabinet CB14 Flashing Lights RB1, Control Cabinet CB15 RD1, RD2, & Tail Lights RB1, Control Cabinet CB16 Dynamic Retard Lights RB3, Control Cabinet CB17 Manual Back-up Lights RB3, Control Cabinet CB18...
Page 155 SECTION E ELECTRICAL PROPULSION COMPONENTS INDEX ELECTRICAL PROPULSION COMPONENTS ......... . . E2-1 General System Description .
Page 156 1. Electric shock can cause serious or fatal injury. Only qualified electrical maintenance per- sonnel should perform electrical testing. Use caution during test procedures to protect per- sonnel from injury. All potential testing should be considered hazardous and proper precautions are necessary. 2.
Page 157: Electrical Propulsion Components
The electric propulsion and control system of the The Statex III control system electronics provide all of Komatsu truck consists of an engine driven alternator the functions necessary to initiate and regulate opera- and cooling air blower, control system, wheel motors, tion of the truck.
Page 158 System Operation The output of the FM528 rectifier panel is variable high voltage DC current, used to power the Motorized When the operator depresses the accelerator foot Wheels. A full wave bridge in the panel rectifies the 3- pedal to propel the truck, two signals are generated. phase input voltage from the Alternator to DC.
Page 159 • Speed restrictions during overspeed and other using the PTU. operating restrictions if faults occur. Previous control systems provided on Komatsu trucks • Event data for technicians through the 2-Digit required system adjustments to be made by removing Diagnostic Display panel.
Page 160 FB cards in the FL275 panel are not field repairable. Should one of the cards become inoperable, it should be returned to the Komatsu Distributor under the GE Unit Exchange Program. Some of the components on the cards are sensitive Cards should be packed in a special shipping con- to static electricity.
Page 161: Computer Description
Throughout the execution of the program, the micro- essential to properly maintaining and troubleshooting processor acts like a traffic officer; taking in instruc- the Komatsu truck control system. This information is tions, interpreting them, and acting accordingly in order presented as additional background information con- to process instructions to the output.
Page 162 “configuration download software”, allows the end user The micro-processor, located on the CPU card (mine) or Komatsu Distributor to select, via an easy to (17FB101 or 17FB144), in the FL275 panel is set up use, menu driven program screen, any one of a num-...
Page 163 Propulsion Retarding As part of the total software package, a particular When the operator presses the retard pedal, accelera- group of regulatory software commands is included tion is canceled and the propulsion contactors are called a “state machine”. The state machine controls dropped out.
Page 164: 2-Digit Display Panel
2-DIGIT DISPLAY PANEL The 2-Digit Display panel (Figure 2-1.), located in the control cabinet, consists of the following: • Two digit “event” number display, • “First” LED • “Last” LED • “Previous (up arrow) search key • “Next” (down arrow) search key •...
Page 165: Frames
FRAMES that type) will not be decayed by the Decay Active Events Count. Every few seconds the system also collects “frames” which are bits of time. The time duration of each frame Running Count is set using the PTU, in increments of 0.01 seconds. This is the total count of all events of this type seen Frames are collected right after all of the systems' since Running Count was last cleared by the PTU.
Page 166: Subcode Descriptions (Table Ii)
Lockout limit (lockout_limit) EVENT SEQUENCE This is the limit on the number of faults which may The 2-Digit Display shows the event code numbers for occur until the Dump Override Switch (DOS) will no all event types which have Active Event Counts greater longer clear the restriction.
Page 167 NOTE: The information listed under “Event Values” provides additional detail for each event and is described as follows: Decay Time ..How long events are held in “active count” memory (in seconds). Lock Limit .
Page 168 TABLE I. 2-DIGIT DISPLAY PANEL CODES (Cont.) EVENT VALUES EVENT EVENT DETECTION EVENT RESTRICTION Decay Lock Accept Window CODE DESCRIPTION INFORMATION Time Limit Limit Limit System Event • In ACCEL: No propel and MF Contactor command and MF Contactor turn on SYSFLT light. feedback do not agree.
Page 169 TABLE I. 2-DIGIT DISPLAY PANEL CODES (Cont.) EVENT VALUES EVENT EVENT DETECTION EVENT RESTRICTION Decay Lock Accept Window CODE DESCRIPTION INFORMATION Time Limit Limit Limit System Event • In ACCEL: No propel and RP8 Contactor command RP8 Contactor turn on SYSFLT light. and feedbak do not agree.
Page 170 TABLE I. 2-DIGIT DISPLAY PANEL CODES (Cont.) EVENT VALUES EVENT EVENT DETECTION EVENT RESTRICTION Decay Lock Accept Window CODE DESCRIPTION INFORMATION Time Limit Limit Limit System Event Current in Motor 1 armature • In ACCEL: No propel and exceeds limits for a preset Motor 1 turn on SYSFLT light.
Page 171: Table I
TABLE I. 2-DIGIT DISPLAY PANEL CODES (Cont.) EVENT VALUES EVENT EVENT DETECTION EVENT RESTRICTION Decay Lock Accept Window CODE DESCRIPTION INFORMATION Time Limit Limit Limit System Event Out of limit (±1V) for 4 sec- • In ACCEL: No propel and onds.
Page 172 TABLE I. 2-DIGIT DISPLAY PANEL CODES (Cont.) EVENT VALUES EVENT EVENT DETECTION EVENT RESTRICTION Decay Lock Accept Window CODE DESCRIPTION INFORMATION Time Limit Limit Limit Motor 2 is over a specific Motor 2 Over Turn On Motor Light temperature limit. Temperature Check for: Same as No.
Page 173 TABLE I. 2-DIGIT DISPLAY PANEL CODES (Cont.) EVENT VALUES EVENT EVENT DETECTION EVENT RESTRICTION Decay Lock Accept Window CODE DESCRIPTION INFORMATION Time Limit Limit Limit Alternator field current slow Alternator Field to decay. Recorded in memory only. Current Level Check for: Defective shunt, iso-amp, or FB102/140 card.
Page 174 TABLE II. 2-DIGIT DISPLAY PANEL SUBCODES PRIMARY SUBCODE CODE TERM DESCRIPTION ANALOG OUTPUT AF_CURR_REF D/A Commanded to output >10 volts for over 0.05 seconds MF_CURR_REF D/A Commanded to output >10 volts for over 0.05 seconds BRKBLV D/A Commanded to output >10 volts for over 0.05 seconds ENGRPMCMD D/A Commanded to output >10 volts for over 0.05 seconds SIG1...
Page 175 TABLE II. 2-DIGIT DISPLAY PANEL SUBCODES (Cont.) PRIMARY SUBCODE CODE TERM DESCRIPTION ANALOG INPUT VOLTS_15P A/D Scaled output > 16.5 or <13.5 for 0.1 seconds VOLTS_15N A/D Scaled output > -13.5 or <-16.5 for 0.1 seconds LO_BATT_VOLT A/D Scaled output < 15.0 for 4.0 seconds HI_BATT_VOLT A/D Scaled output >...
Page 176 TABLE II. 2-DIGIT DISPLAY PANEL SUBCODES (Cont.) PRIMARY SUBCODE CODE TERM DESCRIPTION ENGINE SENSOR WARNING COOLANT PRESSURE Coolant pressure in warning zone for 10 sec. OIL PRESSURE Oil pressure in warning zone for 10 sec. CRANKCASE PRES- Crankcase pressure >16 in. H O for 5 sec.
Page 177: Portable Test Unit (Ptu)
Do not type the quotation spare battery pack are desirable. marks when entering commands on the PTU. Control software provided by GE or Komatsu on a 3.5" (Refer to the chart below.) Other operations floppy disk must be transferred to the PTU hard disk...
Page 178: Software Installation Preparation
NOTE: To determine the latest version of software A batch file to be selected to start software code, contact your Komatsu Distributor. If new code is installation on the PTU if the PTU communi- required, the current disk can be obtained.
Page 179 4. If the floppy disk drive containing the diskette is PTU/Truck Communication Problems designated drive “B”, type “b:install1” Communication problems will occur if the amount of “b:install2” and press [ENTER] key. DOS free memory available on the PTU is less than 5.
Page 180: The Main Menu
THE MAIN MENU “VIEW PTU SAVED FILES” Used to examine the contents of saved event files The main menu, titled GE OHV STATEX III Enhanced in the PTU. No password is required. Can only be MENU (or GE OHV STATEX III MENU if version 14 is used to playback events already stored in a file- installed) as shown in Figure 2-2, illustrates the major name.
Page 181 E02016 2/02 Electrical Propulsion Components E2-25...
Page 182: Configuration (Cfg) File Conversion
CONFIGURATION (CFG) FILE CONVERSION When new GE software code is installed on the PTU to replace older versions of software, it will not contain the existing truck configuration data (overspeeds, serial numbers, option choices etc.) already in current truck files. The Configuration Conversion Tool (“UPDATE CFG VERSION”...
Page 183 FIGURE 2-6. CONFIGURATION FILE CONVERTER MENU (Enhanced Vers. 1.00 Shown) 4. Exit back to the GEOHV STATEX III Menu, use For the following example, “UPDATE v12.10 STD the arrow keys to highlight “QUIT MENU” and CFGS” was selected and the screen in Figure 2-7 press [ENTER] to return to DOS.
Page 184 Files listed under “OLDOEMCFG” are the old umn heading when you begin typing. This means the OEM files created by Komatsu and given to the file name is being changed, but the file has not yet mine to create the previous release configura- been created.
Page 185 18. Use the DOWN arrow key and move the cursor to 22. Press [S]. Note the computer went directly to the the next file name. second file and created it, and went on to the third file and created it. Note also that all asterisks (*) 19.
Page 186: Statex Configuration Files
“510E”, “685E” save a configuration file for a specific truck. and “830E” to separate configuration files. NOTE: If additional directories as described above are 1. Turn on the PTU. When the DOS “C:>” prompt desired, the new directories MUST be created using appears, type “gemenu3E”...
Page 187 “1) Select A Truck Configuration . . .” When many files are listed, it is helpful to sort the file names in a different order from what they appear. For Note: A truck configuration must be selected before example, to sort the files by truck ID, press the [3] key. menu choices 1 through 8 can be used.
Page 188 FIGURE 2-10. TRUCK CONFIGURATIONS SCREEN (830E Truck Sample Data) “2) View Truck Configuration: Data Curves . . .” or press [2]. An example of a model 830E truck configuration is shown in Figure 2-10. NOTE: The following screens are “view only”. No changes can be made.
Page 189 FIGURE 2-12. TRUCK COMPONENT SERIAL NUMBERS “3) Change/View Serial and Model Numbers . . .” “4) View Options . . .” NOTE: The options on this screen can be changed 1. Use the down arrow key to move the cursor to the only by the manufacturer.
Page 190 The following list defines each option: j. Optional motor 2 temperature sensor installed Y: Motor 2 temperature sensor option is a. GE engine control installed. Y: “Fuel Saver” circuitry is installed. The N: Ignore this input. engine, accelerator and retard pedals inter- face with the FL275 panel.
Page 191 “5) Change/View Truck Specifics . . .” b. Ignore high idle switch when empty NOTE: If values are changed on the TRUCK SPECIF- ICS SCREEN, the truck MUST be re-programmed Y: Operator request for high idle is ignored if before the changes will be in effect. sensors indicate truck is empty.
Page 192 e. Engine full load rpm value i. Percent retard pedal travel Off request Used when the manual horsepower limit set is Used to enter the percent of pot reference “N”. Sets the engine rpm value that the control volts at which the retard pedal is calibrated to system will maintain by automatically adjust- have zero retard request.
Page 193 “6) Change/View Overspeeds . . .” Speed at which overspeed retarding is released in miles per hour for an empty truck. The OVERSPEEDS ENTRY SCREEN is used to enter d. Empty speed override . . . mph the desired speed settings for overspeed pickup, over- speed dropout, speed override, and the maximum Speed override value in miles per hour for an retard speed control speed.
Page 194 “7) Save a Truck Configuration, filename: . . .” rently installed on its trucks, but it is strongly recom- mended that a file naming system be established. NOTE: If the configuration file is to be saved into a directory other than the directory shown at the end of line 8), the new directory must be specified before NOTE: The file name length is limited to 8 characters “Save a truck configuration, .
Page 195 FIGURE 2-17. TRUCK CONFIGURATION FILE LIST (Sample file name shown added to the list) “8) Save Directory: . . .” 6. Press [ENTER] to save the new file name into the directory shown on line 8). At the end of line 8) a directory is displayed for storing 7.
Page 196 Level 2 has a privilege level of 1000. It must not keypad as a numeric keypad and hence produces the be less than 300 or greater than 1099. This wrong characters. password can be set by Komatsu or the mine. PTU USER PRIVILEGE LEVELS Level Privelege...
Page 197: Programming The Truck
PROGRAMMING THE TRUCK Activate The PTU Mode 1. Use the arrow keys to move the cursor to the The following procedures should be followed to pro- “PTU TALK TO TRUCK” selection on the main gram a new truck or reprogram an operational truck menu and press [ENTER].
Page 198 FIGURE 2-19. PTU MAIN MENU Check Object Code Version 2. If code has not been installed, the truck CPU is Before downloading configuration files to the truck not programmed, and an error message will CPU, use the cursor to select “OBJ CODE V0.00” (or appear as shown in Figure 2-20.
Page 199: Download Configuration Files
Download Configuration Files 5. Use the arrow keys to move the cursor to desired program truck selection. Download configuration files into the CPU on the truck a. “NO, Return to Engine Stopped Test as follows: Menu”This selection will take the computer 1.
Page 200 DATE AND TIME 4. If the date and time displayed is correct, press [ENTER] at the “No, Do not reset date and time” When the initial programming of a truck is completed, selection. the date and time should be set. 5.
Page 201: Event Data
EVENT DATA The “EVENT DATA MENU” selection from the SPE- PTUSTX: 1.2.1 EVENT DATA MENU CIAL OPERATION MENU allows the technician to view event data stored in the CPU, save the event data to a Special Operation file and to erase event data when storage of the infor- Events stored mation is no longer necessary.
Page 202 PTUSTX: 1.2.H RESET HARDWARE STARTUP EVENT To reset the hardware startup event, control power must first be cycled Please exit this screen, and then turn off the control power while the PTU is at the PTU MAIN MENU screen. observe the normal 2 second shutdown sequence. Remember to wait about 20 seconds after the panel powers up before attempting to use the PTU to communicate with the GE control system.
Page 203: Table Iv
STATISTICAL DATA “VIEW COUNTERS” The Statistical Data Collector uses the memory capa- The STATISTICAL COUNTERS SCREEN displays the bility of the computer to record and store hundreds of number of times various operations have occurred in system parameters unique to each individual truck. the history of the truck operation or in how many sec- These parameters are divided into two types;...
Page 204: Statistical Data Codes - Counters (Table Iii)
STATISTICAL DATA CODES - COUNTERS Statistical Data Collector uses Parameter The fourth counter, “This Day”, keeps a moment by Counters and Parameter Profiles to record operating moment count of occurrences of the parameter just as conditions for various occurrences on the truck. “This Qtr”, except the “This Day ”...
Page 205: Table Iii
TABLE III. STATISTICAL DATA CODES - COUNTERS DESCRIPTION UNITS COUNT CONDITIONS Engine Operating Hours Hours Number of hours engine has operated above 450 RPM Number of hours wheel was powered in either propulsion or retard mode and: Wheel #1 Operating Hours Hours .
Page 206 TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.) DESCRIPTION UNITS COUNT CONDITIONS Number of times Propel Contactor sequence has been completed or Propel Propel Mode Occurrences mode entered Coast Mode Occurrences Number of times Coast mode entered P1 Pickup Occurrences Number of times P1 feedback has changed from false to true P2 Pickup Occurrences...
Page 207 TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.) DESCRIPTION UNITS COUNT CONDITIONS Number of times “SPECIAL OPERATION” menu has been selected at “PTU Special Operation Occurrences MAIN MENU” Events Erased Occurrences Number of times PTU has been used to erase event data Number of times “NORMAL OPERATION”...
Page 208 TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.) DESCRIPTION UNITS COUNT CONDITIONS Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences FORWARD Occurrences REVERSE Occurrences Analog Output Occurrences Analog Read Back Occurrences Analog Input Occurrences Frequency Input Occurrences Startup Fault Occurrences Diode Fault Occurrences Motor 1 Occurrences...
Page 209 TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.) DESCRIPTION UNITS COUNT CONDITIONS Overspeed Occurrences Speed Retard Occurrences Exceeded Retard Overcurrent Occurrences Horsepower Low Occurrences HP Limit Exceeded Occurrences Engine Overspeed Occurrences Exceeded Engine Oil Pres- Occurrences sure Warning Engine Oil Pres- Occurrences sure Shutdown Engine Coolant...
Page 210 TABLE IV. STATISTICAL DATA CODES - PROFILES CURRENT DESCRIPTION COUNT CONDITIONS BUCKET No. VALUE (AMPS) 500 & below 501 to 750 This is a histogram of Motor #1 armature current in propulsion 751 to 850 mode..Sample time is 1.0 second 851 to 950 M1 Amps Propel .
Page 211 TABLE IV. STATISTICAL DATA CODES - PROFILES (Cont.) CURRENT DESCRIPTION COUNT CONDITIONS BUCKET No. VALUE (AMPS) 0 to 100 101 to 125 This is a histogram of Motor Field current in propulsion mode. 126 to 150 ..Sample time is 1.0 second 151 to 175 MF Amps Propel .
Page 212 TABLE IV. STATISTICAL DATA CODES - PROFILES (Cont.) TEMP RANGE DESCRIPTION COUNT CONDITIONS BUCKET No. (° C) -40 to 100 101 to 110 This is a histogram of Motor #1 temperature. 111 to 120 ..Sample time is 60.0 seconds 121 to 130 M1 Temp °C .
Page 213 TABLE IV. STATISTICAL DATA CODES - PROFILES (Cont.) TEMP RANGE DESCRIPTION COUNT CONDITIONS BUCKET No. (° C) 20 & below 21 to 40 This is a histogram of Alternator Field Static Exciter temperature. 41 to 50 ..Sample time is 60.0 seconds 51 to 60 .
Page 214: Truck Specific Information
This selection permits reviewing the setup informa- changed. If changes are required, use the “TRUCK tion programmed into the truck configuration file by SETUP (CFG)” selection from the GE OHV STATEX III Komatsu. (These options cannot be changed by MENU. mine personnel.) •...
Page 215: Temporary Truck Settings
TEMPORARY TRUCK SETTINGS Selections available on this menu are: • “SPEED SETTINGS” When troubleshooting a truck, it is sometimes neces- sary to make temporary changes to the system. The New speed setting values may be typed over the TEMPORARY TRUCK SETTINGS MENU allows existing values to override the current configuration changes to be made to speed settings, retard current file settings.
Page 216: Saving Data
MISCELLANEOUS FEATURES Note: The changes made above are only temporary. When proper adjustment value been determined, the truck configuration file should be SAVING DATA permanently changed by entering this value on the Various screens showing event data, digital input and TRUCK SPECIFICS SCREEN.
Page 217: Ptu Abbreviations
PTU ABBREVIATIONS OTHER MENU SELECTIONS Due to limited screen space, many abbreviations are Software menu items not covered in this section of the necessary for displaying information on the various manual are normally used for truck checkout and trou- screens. A definition of each abbreviation and special bleshooting only.
Page 218: Miscellaneous Electrical Propulsion Components
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS ALTERNATOR Refer to applicable GE publication for service and maintenance procedures. ELECTRIC WHEEL MOTORS Refer to applicable GE publication for service and maintenance procedures. RETARDING GRIDS Refer to applicable GE publication for service and maintenance procedures. (Cooling Blower Only). FIGURE 2-28.
Page 219 Disassembly 3. Rotate potentiometer counterclockwise until mounting slots contact the mounting screws and 1. Remove screws on cable clamps (1, Figure 2-28 tighten screws (5) to 10-20 in lbs. (1.13-2.26 N- or 2-29) and potentiometer cover (6). m) torque. 2. Remove potentiometer mounting screws (5) and 4.
Page 220: Cooling Blower Warning System
COOLING BLOWER WARNING SYSTEM The Komatsu truck is equipped with a cooling blower to supply cooling air to the alternator, exciters and wheel motors. The cooling blower warning system which consists of a pressure switch, warning light, buzzer, and an adjust- able time delay controlled by the CPU in the FL275 panel.
Page 221: Electrical Control Cabinet
ELECTRICAL CONTROL CABINET The following pages illustrate the electrical control cab- inet and components located inside the cabinet and the control cabinet junction box located on the rear of the cabinet (Figure 2-37). All contactors and the reverser in this control cabinet are electrically operated - no air supply is required.
Page 222 FIGURE 2-32. ELECTRICAL CONTROL CABINET (Component Location, Front View. See Figure 2-37 for Relay Board Panel inside R.H. Door) 1. Alternator Field Contactor 10. Diagnostic Data Reader Connector 2. Motor Field Contactor 11. Statex Channel A (PTU) Connector 3. Retard Power Contactor No. 2 12.
Page 223 FIGURE 2-33. CONTROL CABINET, VIEW A FIGURE 2-35. CONTROL CABINET, VIEW B 1. Diode Board DB1 1. Propulsion Load Con- 2. Relay Board RB6 trol Panel (PLCP) FIGURE 2-34. CONTROL CABINET, VIEW C FIGURE 2-36. CONTROL CABINET, VIEW D 1. Isolation Amplifier #3 7.
Page 224 1. Fault Detection Panel 2. Alternator Field Discharge Resistor 3. Motor Field Discharge Resistor 4. Control Power Diode 1 5. Control Power Diode 2 6. Control Power Relay 7. Alternator Field Relay 8. Shunt 7 9. Shunt 6 10. Shunt 2 11.
Page 225 FIGURE 2-38. RETARDING GRIDS & CONTACTORS (R.H. DECK) 1. Retarding Grids and Blower(s) 2. Retarding Contactor Box E02016 2/02 Electrical Propulsion Components E2-69...
Page 226 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS NOTE: Some components listed may be optional equipment. GRR ..... Ground Relay Resistor ACC .
Page 227 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 17FB100 ......Power Supply 17FB103 ....Digital Input/Output 17FB101/144 .
Page 228 NOTES E2-72 Electrical Propulsion Components 2/02 E02016...
Page 229 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE TABLE OF CONTENTS SECTION............... PAGE GENERAL INFORMATION .
Page 230 4.2 Loaded Truck - 2 Speed Overspeed Settings Check ....... E3-35 4.4 Other Speed Events Checks.
Page 231: General Information
I N F O R M A T I O N This checkout procedure describes test and adjustment procedures for the G.E. STATEX III Electric Wheel Drive Systems used on Model 445E, 510E, 630E, 685E, 730E, and 830E electric drive trucks with the following alternator and wheelmotor combinations.
Page 232: Communications Port Check
C O M M U N I C A T I O N S P O R T C H E C K PTU Hookup NOTE: The following procedure will verify correct PTU hookup and verify communication between the PTU and the CPU. Additionally, all previous event data can be cleared prior to performing the checkout procedure.
Page 233 PTUSTX: 1.2.1 EVENT DATA MENU Special Operation Events stored ( ) VIEW EVENT DATA Event Summary and Details ( ) reset hardware startup event ( ) GE engineering format event data ( ) EXIT FIGURE 3-2. EVENT DATA MENU (Requires Control System Reset) 9.
Page 234: Sequence Tests - (Engine Not Running)
1.0 SEQUENCE TESTS - (Engine not running) Preparation & Setup It is assumed the truck has been programmed using the correct Truck Configuration File and GE Statex III Enhanced version 1.00 (if truck is equipped with a 17FB144 CPU card) or version 14.00 (if truck is equipped with a 17FB101 CPU card) or later software prior to proceeding with the following tests.
Page 235: Throttle System Check And Adjustment
1.1 Throttle System Check and Adjustment NOTE: If the truck is an early production unit, not equipped with the Fuel Enhancement (“Fuel Saver”) system, refer to step 1.1.1. If the truck is a later or current production unit, refer to step 1.1.2.
Page 236 9. With throttle pedal fully depressed, measure the following: ACTION IF OUT CIRCUIT ACC CARD VOLTS PTO COUNTS OF TOLERANCE TZ6661 3.80 (approx.) 203 -4/ +10 510(+) Replace ACC card or EB2635 4.35 (approx.) 215 -4/ +10 pedal 952(-) EC1806 4.05 (approx.) 215 -4/ +10 10.
Page 237 FIGURE 3-4. PTU MAIN MENU 1. Record the accelerator pedal % (percent) values shown on the MONITOR ANALOG INPUT CHANNELS screen: a. Pedal OFF - note on paper the % value shown on the PTU screen for “acc pedal”. (For example, 11.3) b.
Page 238 NOTE: If either pedals' “off %” is greater than 15% before making the pedal setting changes to the configuration file, the system will interpret the pedal as being pressed and may cause the contactors to energize. 3. Exit to the NORMAL OPERATION MENU, GE STATEX III PTU MAIN MENU and exit to the GE OHV MENU.
Page 239 d. From 74N to 710: Read .09 ±.10 vdc. 3. With retard pedal depressed just until retard contactors pick up, measure the voltage between the following circuits: a. From 74N to 710: Read 0.20 ±.20 vdc. If out of tolerance replace RET card. b.
Page 240 PTU SETUP • If not done previously, Set up PTU using the communication port in the electrical cabinet. • Select the MONITOR REAL TIME DATA screen as follows: a. From the GEOHV STATEX III MENU, select “PTU TALK TO TRUCK” and press [ENTER]. b.
Page 241: Reverser And Propulsion Contactors Check
FIGURE 3-8. MONITOR REAL TIME DATA SCREEN NOTE: PTU abbreviations shown with a line above and below after the following steps indicate highlighted items to be observed on PTU display screen. Highlighted items will be preceded by an “equals” sign to indicate a digital input is “true” and a digital output is “ON”. Steps 1.3, and 1.4 may also be checked using the ACCELERATE STATE LOGIC SCREEN and step 1.5 may be checked using the RETARD STATE LOGIC SCREEN if desired.
Page 242 7. Verify feedback signals are present: MFFB P1FB (P2FB) GFFB GFRFB 8. Release throttle. Propulsion contactors should drop out. 9. Move Selector Switch to REVERSE. 10. Verify that Reverser shifts to reverse position (to the left). REVIN a. Verify the feedback signal: REVFB 11.
Page 243: Retard Contactors Operation Check
1.5 Retard Contactors Operation Check 1. Put Selector Switch in FORWARD and depress retard pedal. FORIN RS 2. Verify that the contactors pick up in the following sequence; RP1, RP2, MF, GF, and GFR then RP3, RP4, RP5 (and RP6, RP7, RP8, and RP9 if used). RP1 RP2 MF GF GFR RP3 RP4 RP5 RP6 RP7 RP8 RP9 a.
Page 244: Override Operation Check
a. “RETARD” should be highlighted: RETARD 3. Momentarily jumper from circuit 71 to terminal “A” on GFIP. GFAULT 4. All contactors should remain energized. Event code 01 should appear on two digit display. Elec- tric system fault light should come on. 5.
Page 245: Anti-Reversal Function (Ar) Check
1.9 Anti-Reversal Function (AR) Check • Disconnect wheel motor speed sensor wires 77, 77A, 714 & 714A in control cabinet. Jumper circuit 77 to 714. Jumper circuit 77A to 714A. • Connect an oscillator to circuit 77 and 77A at control cabinet terminal board. Do not turn oscil- lator on.
Page 246: Hoist Interlock Operation Check
4. Verify that propulsion contactors MF, P1/(P2), GF and GFR drop out and then retard contactors RP1, RP2, MF, GF, GFR, RP3, RP4, RP5, (and RP6-RP9 if used) pick up and the Dynamic Retard Light in the cab comes on. RP1 RP2 MF GF GFR RP3 RP4 RP5 RP6 RP7 RP8 RP9 a.
Page 247: Motor Blower Fault Light Operation Check
10. Propulsion contactors should drop out. Operate override switch. 11. Contactors should not pick back up. Release override switch. 12. Replace metal washer or reconnect 71F. The contactors should not energize. 13. Release throttle. Put Selector Switch in NEUTRAL, then to REVERSE. 14.
Page 248: Digital Input/Output Signals Tests - Fl275 Card Panel
2.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL • Connect PTU at control cabinet as described previously. • Turn PTU On and type “gemenu3e” (or “gemenu”, for version 14.00) at the C:> prompt. Press [ENTER]. 2.1 Setup Manual Digital Input/Output Test on PTU 1.
Page 249: Digital Input Checks
2.2 Digital Input Checks 1. The two digit diagnostic display panel should have a 00 event code to indicate that all previous event codes have been cleared. If not, press reset switch to clear codes. 2. For the digital inputs listed below, do the PROCEDURE TO ACTIVATE as specified, and verify that the display status of the digital input name on the MANUAL DIGITAL OUTPUT TEST SCREEN changes from false (regular display) to = true (inverse display), unless otherwise noted.
Page 250 PROCEDURE TO DI NAME DESCRIPTION FUNCTION ACTIVATE In control cabinet, jumper 28 volts from 712 to 44R to sim- = true (inverrse display) = brake applied = 28v input SERVICE BRAKE PRES- SRVBRKPSW ulate service brake applied. SURE SWITCH Remove jumper. false (regular display) = brake released = 0v input SELECTOR SWITCH Move selector switch to FOR-...
Page 251: Digital Output Checks
2.3 Digital Output Checks • For each of the digital outputs listed in the following tables, perform the procedure as specified in steps 1 and 2, and verify the results on the MANUAL DIGITAL OUTPUT TEST SCREEN as noted in the following table. Be sure to restore any switch settings and wiring changes to their original condition before moving on to check the next digital output.
Page 252 OUTPUT DEVICE CHECKOUT DO NAME DESCRIPTION DEVICE STATE PTU DISPLAY-DEVICE PTU DISPLAY-FEEDBACK *NOTE: P11, RP11, & RP22 are digital outputs (not physical devices) wired in parallel with outputs P1, RP1, & RP2 respectively. These outputs are only used if airless contactors are installed. If installed, test by activating both outputs (P1 and P11), (RP1 & RP11), (RP2 &...
Page 253 OUTPUT DEVICE CHECKOUT DO NAME DESCRIPTION DEVICE STATE VERIFICATION Output AFSE = on Measure 28v from AFSE terminal +25v (wire 711A) to GND. ALTERNATOR FIELD AFSE STATIC EXCITER Output AFSE off Measure 0v from AFSE terminal +25v (wire 711A) to GND. Output MFSE = on Measure 28v from MFSE terminal +25v (wire 711B) to GND.
Page 254: Analog Input Signals Tests - Fl275 Card Panel
3.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL The PTU will be used to test analog inputs to the FL275 panel analog I/O Card, to verify proper truck wiring, control panel wiring and component operation. • Connect PTU at control cabinet as described previously. •...
Page 255: Analog Input Checks
3.2 Analog Input Checks • The two digit diagnostic display panel should have a 00 event code to indicate that all previous event codes have been cleared. If not, press reset button to clear codes. • For each of the analog inputs listed, perform the test procedure specified, and verify the results on the MONITOR ANALOG INPUT CHANNELS screen.
Page 256 2. MOTOR 1 ARMATURE CURRENT - ISOA3 : ..motor 1 amps = 0.0 (Screen value amps = 1000 x input voltage). a. Test zero offset on isolation amplifier. Place a digital voltmeter between terminals “D” (+) and “F”...
Page 257 6. RETARD SPEED POT SETTING: ... . . ret spd pot set = 0.0v a. Close Retard Speed Control Switch in cab. b. Vary Retard Speed Control adjustment from minimum to maximum. Read 0.0 volts at minimum to +19 ±0.50 volts at maximum on PTU screen for non-Fuel Saver truck.
Page 258 9. ALT. TERTIARY OVERCURRENT - ISOA6 : alt tert current = 0.0 ac amps (Screen value AC amps = 275 x DC input voltage). NOTE: Prior to testing, the PTU screen will display erroneous data. a. Test zero offset on isolation amplifier. Place a digital voltmeter between terminals “D” (+) and “F”...
Page 259 f. Reverse polarity of input. Jumper circuit 71 to terminal “C” and jumper circuit 710 to terminal “A” at VMM1. Verify negative value of output voltage measured in step e. and negative value on PTU screen. g. Remove jumpers and voltmeters. Restore all disconnected wiring. 12.
Page 260 15. MOTOR 2 TEMPERATURE ..motor 2 temp = 0.000 V; 0.0° C a. Disconnect motor 2 temperature sensor wires 722F and 722H routed to wheel motor from terminal board in control cabinet. b.
Page 261 20. +15 VOLT SUPPLY ......15 v positive = 0.0 Screen should read +15.0 ±0.3 volts. 21.
Page 262: Frequency Input Checks
3.3 Frequency Input Checks • For each of the frequency inputs listed below, perform the test procedure specified, and verify the results on the MONITOR ANALOG INPUT CHANNELS screen as noted. Be sure to restore any switch settings and wiring changes to their original condition before moving on to check the next frequency input.
Page 263 4. MOTOR 2 SPEED ..... . Motor 2: 0.0 rpm; 0.0 mph a. Connect oscillator to circuits 714 and 714A at control cabinet terminal board. Repeat same test procedure for Motor 2 as used for Motor 1.
Page 264: Speed Event Checks
4.0 SPEED EVENT CHECKS Preparation & Setup • Always disconnect 74C at GFR for static testings. Failure to do so may result in damage to bat- tery boost SCR and/or dead batteries. • If the truck is equipped with the Two Speed Overspeed, remove and insulate circuit wire 73LS going to the control cabinet junction box.
Page 265: Other Speed Events Checks
4.1 Single Speed Overspeed Truck - Overspeed Settings Check 1. While observing the RETARD STATE LOGIC SCREEN, increase the oscillator frequency from minimum until the retard contactors RP1 and RP2 pick up in overspeed. 2. Verify the M1- SPD and M2 - SPD mph readings agree with values recorded from the truck con- figuration file OVERSPEEDS ENTRY SCREEN.
Page 266 4. Turn the oscillator frequency to maximum. Verify that the RP contactors pick up in the sequence listed, as the oscillator frequency is slowly decreased. a. 3 Step Extended Range Retarding - RP3, RP4, and RP5 contactors. b. 7 Step Extended Range Retarding - RP3, RP4, RP5, RP6, RP7, RP8, and RP9 contactors. 5.
Page 267: Retard Speed Control System Check
5.0 RETARD SPEED CONTROL SYSTEM CHECK Preparation and Setup • Disconnect external 77 and 714 wires (routed to the wheel motors) from control cabinet termi- nal board. • Jumper 77 to 714, and jumper 77A to 714A. • Connect an oscillator to circuits 77 and 77A. •...
Page 268: Retard Pot Maximum Setting Check
5.2 Retard Pot Maximum Setting Check 1. Set the retard speed control potentiometer (in cab) to maximum and turn the retard speed con- trol switch to the On position. Note the retard speed control light turns On. 2. Turn on oscillator, and the retard contactors should pick up. If not, increase frequency slightly until the contactors pick up.
Page 269: Load Test Using Truck Retard Grids
Top shunt swings to upper position, bottom shunt swings to bottom position. b. For 830E or 685E trucks, left shunt swings to left position, right shunt swings to right position. If load test must be run any longer than to just read horsepower, the motor field leads must be disconnected to prevent overheat- ing of the motor fields.
Page 270 NOTE: Net horsepower may be affected by many variables such as ambient temperature, altitude, fuel temperature, parasitic losses, tertiary losses, engine condition etc. Parasitic horsepower loss values that have been corrected for temperature and altitude may be obtained from the Komatsu Distributor.
Page 271: Motor Field Current Check In Retarding
7.0 MOTOR FIELD CURRENT CHECK IN RETARDING NOTE: If wheelmotors were not installed on truck during factory check-out, this test must be performed during truck check-out at mine site. Setup PTU • Select the AUTOMATIC LOAD BOX TEST screen as follows: a.
Page 272: Miscellaneous Component Test And Adjustment
RUN (On) position. • On 830E trucks the key switch must first be turned Off to shut down the engine, and then returned to the RUN (On) position to maintain hydraulic pressures. The hydraulic pressures will bleed off if the key switch is not left in the RUN (On) position.
Page 273: Blower Loss Pressure Switch Adjustment
8.2 Blower Loss Pressure Switch Adjustment NOTE: If wheelmotors were not installed on truck during factory check-out, this test must be performed during truck check-out at mine site. Be certain the rear axle box door is closed and the rear wheel covers are installed. 1.
Page 274: Battery Boost Adjustment
8.5 Battery Boost Adjustment 1. Turn On key switch and control power. Start engine and place selector switch in NEUTRAL. 2. Setup the PTU to read values on the AUTOMATIC LOAD BOX TEST SCREEN. 3. Connect voltmeter to R1 battery boost resistor, 74C (+) and 74AA (-). 4.
Page 275: Motor Rotation Test
• Check each wheel motor individually with the following cable hookup: 1. Place a jumper across the left wheelmotor armature (from cable 7GA1 (7G10 on the 830E) to 7J1) to check the right wheelmotor rotation. 2. Depress the accelerator pedal just far enough to enter propel state and the wheels begin to rotate.
Page 276: Ground Fault Checks
8.8 Ground Fault Checks If a ground fault occurs during operation, the Electrical System Fault light will turn On and the amount of leakage to ground will be displayed on the MONITOR ANALOG INPUT CHANNELS screen of the PTU. To isolate a ground fault problem, the following procedures should be followed: 1.
Page 277: Optional Payload Meter (Plm Ii) Check-Out Procedure
9.0 OPTIONAL PAYLOAD METER (PLM II) CHECK-OUT PROCEDURE 9.1 Check The Deck Mounted Lights Turn the payload meter system on by switching the truck key switch to the On position. The payload meter automatically runs a 10 second self test. During the self test the deck mounted lights are On. If they are not all lit, check connections, wiring and bulbs.
Page 278: Miscellaneous Charts
10.0 MISCELLANEOUS CHARTS 10.1 Wheel Motor Gear Ratios WHEEL GEAR RATIO CHART GEAR GE WHEELMOTOR MODEL NO. RATIO TIRE SIZE (xx.xxx : 1) 5GE772YS3, YS4 28.8 30 X 51 5GE776HS8B 2.88 30 X 51 5GE776KS5B, KS7B 23.0 36 X 51 5GE776KS6B, KS8B, KS10B 28.8 36 X 51...
Page 279: Maximum Allowable Truck Speeds
10.2 Maximum Allowable Truck Speeds MAX TRUCK MPH = (MAX. WHEEL RPM x ROLLING RADIUS) ÷ (GEAR RATIO x 168) RPM/MPH CONVERSION FACTOR = MAX. WHEEL RPM ÷ MAX. TRUCK SPEED MPH/RPM CONVERSION FACTOR = MAX. TRUCK SPEED ÷ MAX. WHEEL RPM MAXIMUM TRUCK SPEED CHART FOR GIVEN WHEELMOTOR GEAR MAX.
Page 280: Engine Options
10.3 Engine Options CUMMINS ENGINE OPTION CHART RATED *RETARDING *LOW ENGINE MODEL ENGINE NO LOAD IDLE (No Load) KTA-38 1900 2100 ±75 1675 ±10 750 ±25 KTTA-50-C 1900 2100 ±75 1675 ±10 750 ±25 KTTA-50-C 2000 2200 ±75 1675 ±10 750 ±25 KTTS-50-C 2100...
Page 281 SECTION G DRIVE AXLE, SPINDLE AND WHEELS INDEX TIRES AND RIMS ..............G2-1 FRONT TIRES AND RIMS .
Page 282 REAR AXLE HOUSING ATTACHMENT ..........G4-1 Pivot Pin .
Page 283: Tires And Rims
TIRES AND RIMS The truck tires should be inspected and tire pressure checked with an accurate pressure gauge before each working shift. Tire pressure will vary according to manufacturer and local working conditions. Con- sult tire manufacturer for recommended tire pres- sure.
Page 284: Installation
FIGURE 2-1. FRONT WHEEL ASSEMBLY 1. Valve Assembly 6. Lock Ring 11. Lockwasher 16. Lockwasher 2. Bead Seat Band 7. Wheel Retainer Lug 12. Nut 17. Bent Plate 3. Rim 8. Nut 13. Clamp 18. Hub 4. O-Ring 9. Capscrew 14.
Page 285: Rear Tires And Rims
REAR TIRES AND RIMS If the studs in the rear wheel motor require replace- ment, use a special tool and tighten studs to 540 ft.lbs. (732 N.m) torque. Removal 1. Park truck on level ground and block front wheels. Position a jack in recess of rear sus- pension mount casting as shown in Figure 2-3.
Page 286: Installation
5. Pull straight out on outer wheel assembly and remove. 6. If inner wheel removal is necessary, remove spacer (6, Figure 2-4) by pulling straight out and removing from rear hub. (Refer to Figure 2-6.) Due to its size and weight, always keep person- nel away from a wheel assembly when it is being removed and installed.
Page 287: Rim
7. Secure inner and outer dual tire inflation lines to 1. Place tire and wheel assembly in safety cage bracket on outer rim. Tighten capscrews to and discharge all air pressure from tire. standard torque. 2. Attach a hydraulic bead breaker to the rim by 8.
Page 288: Lubricants
LUBRICANTS TIRE INSTALLATION The proper amount and type of lubricant is key to The preferred method for mounting tires is horizon- successful mounting of radial off-road tires. tally and off of the truck, especially for initial tire mounting on a new truck. For horizontal tire mount- ing, a workman’s stand is recommended for working inside the tire.
Page 289 2. If valve stem and spud assembly were removed, 8. Install lockring (6) and tap into place with lead reinstall in rim. Install valve stem assembly onto hammer. Lockring lug must fit into slot of rim and install spud assembly to inside of rim. rim.
Page 290 NOTES: G2-8 Tires and Rims 04/03 G02004...
Page 291: Wheel Hub And Spindle Assembly
FRONT WHEEL HUB AND SPINDLE WHEEL HUB AND SPINDLE ASSEMBLY 3. Remove any grease lines being used for a group lube or automatic lube system for the steering Removal cylinder and tie rod. Cap all lines. 4. Remove capscrews and washers securing The following instructions will cover the complete brake line junction block (2), and main brake removal, installation, disassembly, assembly and...
Page 292: Spindle Pusher Tool Usage
850° F (454° C). 830E (AFE 32) Capscrew P/N KC7091....1.125 x 7 in. Min. Thread engagement: ... . . 1.50 in.
Page 293: Installation
830E, AFE 32 ..1.125 in. - 12NF tap 830E, AFE 50 ... 1.25 in. - 12NF tap 7. Install capscrews (5) and torque to: 830E, AFE 32 .
Page 294 FIGURE 3-5. SPINDLE AND WHEEL HUB ASSEMBLY 1. Hub 10. O-Ring 19. Cone 2. Capscrews & Lockwashers 11. Cup 20. Cup 3. Cover 12. Disc Brake 21. Capscrew & Flatwasher 4. Oil Fill Plug 13. Brake Support 22. Capscrew & Flatwasher 5.
Page 295: Disassembly
Disassembly 9. If brake disc replacement is required, attach a lifting device to the brake disc (1, Figure 3-6), Note: The preferred method for rebuilding the front remove capscrews (2), and lift and brake disc wheel hub and spindle assembly is to remove these from hub (3).
Page 296: Assembly
Assembly f. Before assembling wheel hub and spindle, wipe the seal faces with lint-free cloth to 1. Assemble brake support, (13, Figure 3-5) to the remove any foreign material and fingerprints. spindle (17), if removed. g. Place a few drops of light oil on a clean cloth 2.
Page 297 b. Install cups in wheel hub bores. c. After cups have warmed to ambient temper- ature, press the cups tight against hub shoul- der as follows: 1.) Inner Cup (20) - Apply 30,000 lbs. (133,450 N) force. 2.) Outer Cup (10) - Apply 23,000 lbs. (102,300 N) force.
Page 298: Wheel Bearing Adjustment
Wheel Bearing Adjustment (Tire Removed) 1. Install bearing retainer (1, Figure 3-9), without shims, with the thickness dimension stamp fac- ing toward the outside. Install all six capscrews (2) with flat washers. Tighten capscrews alter- nately using the following procedure: a.
Page 299 4. Wrap a chain and chain binder (2, Figure 3-10) 11. Loosen all six capscrews until the flat washers around the top half of the tire. Secure chain are free, then select two capscrews 180° apart through the frame. Chain should be tightened and adjacent to the 0.50 in.
Page 300: Steering Cylinders And Tie Rod
STEERING CYLINDERS AND TIE ROD 23. Remove suspension support chain (1, Figure 3- 10) if installed, and all cribbing. Lower truck tire The steering cylinders and tie rod are mounted in the to ground. same manner. The removal and installation instruc- NOTE: The wheel bearing preload should be tions are applicable to both.
Page 301: Removal
Installation 1. Align bearing spacers (10) and rod end (15) with pin bores on spindle and frame. 2. Install pins (4 or 5), capscrews (3) and retainers Use extreme caution when performing mainte- (6 or 7) and secure with locknut (9). Tighten to nance on any vehicle with an active steering sys- 525 ft.
Page 302 FIGURE 3-12. STEERING CYLINDER AND TIE ROD INSTALLATION 1. Tie Rod Assembly 6. Retainer 11. Bearing Retainer 16. Tie Rod Assembly 2. Steering Cylinder 7. Retainer 12. Capscrew 17. Capscrew 3. Capscrew 8. Hardened Washer 13. Lockwasher 18. Locknut 4. Pin 9.
Page 303: Toe-In Adjustment
"Steering Cylinders and Tie Rod, Removal". NOTE: For trucks with adjustable rod ends at both ends of the tie-rod, pin removal is not necessary. 830E Toe-In Data in. (cm) 5. Loosen clamp nuts (18, Figure 3-12) on tie-rod Nominal Tie-rod Length, 144.00...
Page 304 NOTES: G3-14 Front Wheel Hub and Spindle 04/03 G03018...
Page 305: Rear Axle Housing Attachment
REAR AXLE HOUSING ATTACHMENT PIVOT PIN Installation 1. Raise pivot eye into position. Removal 2. Be certain spherical bearing inner race (7) is 1. Park truck on firm, level surface and block front aligned. Install spacers (5, Figure 4-1), cover and rear of all tires.
Page 306: Pivot Eye Bearing
7. Charge front suspension as described in "Oiling Assembly and Charging Procedure", Section "H". 1. Setup an appropriate tool to press spherical 8. Charge rear suspensions with nitrogen to fully bearing (4, Figure 4-2) into bearing carrier (13). extend pistons. Be sure bearing outer race is flush with bearing carrier sides.
Page 307 PIVOT EYE REPAIR Assembly 1. Setup an appropriate tool to press bearing car- If damage occurs to the pivot eye (4, Figure 4-3), it rier (3, Figure 4-2) into the bore of the pivot eye may be necessary to remove it from the rear axle structure (1).
Page 308: Anti-Sway Bar
ANTI-SWAY BAR Disassembly 1. Remove snap rings (4) from bores of both ends Removal of anti-sway bar. 1. Position frame and final drive case to enable 2. Press out spherical bearing (8). use of a puller arrangement to remove anti- sway bar pins (7, Figure 4-4) on the rear axle housing and frame.
Page 309: Rear Axle Housing
REAR AXLE HOUSING REAR AXLE HOUSING WHEEL MOTOR Removal Removal 1. Remove the dump body as outlined in Section 1. Block front wheels to prevent movement. Turn "B". key switch "Off". Wait for 90 seconds to bleed hydraulic pressure from the steering system. NOTE: It is not necessary to remove the rear axle Turn the steering wheel to ensure no hydraulic assembly to service the anti-sway bar or pivot pin.
Page 310: Cleaning And Inspection
5. Disconnect brake, lubrication and electrical con- tions. Replace only with bolts of correct hardness. nections from wheel motor. Refer to Komatsu Parts Catalog for correct part num- ber. Before installation, inspect each capscrew for any defects and number of punch marks. Replace capscrew and related hardware if two punch marks are evident;...
Page 311 SECTION H ® HYDRAIR II SUSPENSIONS INDEX FRONT SUSPENSION ............. H2-1 Removal .
Page 312 NOTES H1-2 Index 5/03 H01015...
Page 313: Front Suspension
FRONT SUSPENSION ® The HYDRAIR II suspensions are hydro-pneumatic components containing oil and nitrogen gas. The oil and gas in the four suspensions carry the gross truck weight less wheels, spindles and final drive assembly. The front suspension cylinders consist of two basic components;...
Page 314: Installation
8. Remove capscrews and washers (1, Figure 2-3) and nuts and washers (2). 9. Remove capscrews and washers (8), and nuts and washers (10). 10. Remove capscrews and washers (6), and spacers (9). 11. Move suspension to a clean work area for disas- sembly.
Page 315 Grade 8 specifications. Replace only with bolts of correct hardness. Refer to Komatsu Parts Catalog for correct part number. Before installation, inspect each capscrew for any defects and NOTE: The “Turn-of-the-Nut” tightening procedure number of punch marks.
Page 316: Turn-Of-The-Nut" Tightening Procedure
“TURN-OF-THE-NUT” Tightening 1.) Mark a reference line on a corner of the hex- agonal capscrew head or nut and the mount- Procedure ing surface opposite this corner as shown. a. Tighten all fourteen capscrews (1, 6, 8, Figure Then mark the position located 60° or 90° 2-3) to 400 ±40 ft .lbs.
Page 317: Bearing Structure Removal
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) Bearing Structure Removal If only rod seals, O-rings, and backup rings (and if nec- essary, bearing structure) are to be replaced, refer to steps below for lower bearing structure removal. 1. Remove lower bearing structure capscrews and hardened washers (18 &...
Page 318: Major Suspension Rebuild
12. Nut 13. Roll Pin 14. Steel Check Ball MAJOR SUSPENSION REBUILD Disassembly NOTE: Refer to your Komatsu Distributor for HYD- ® RAIR II repair information and instructions not covered in this manual. 1. With suspension held in a vertical position (end cap up), remove capscrews (1, Figure 2-5) and hardened washers (2).
Page 319: Assembly
Assembly 4. Install new backup rings and O-rings (14 & 15, Figure 2-7) in end cap grooves. Backup rings NOTE: All parts must be completely dry and free of for- must be positioned toward the flange on the end eign material. Lubricate all interior parts with clean cap.
Page 320: Pressure Test
PRESSURE TEST After rebuild is complete, suspension assembly should be tested for leakage. When pressure testing, suspension must not be allowed to extend. Assembly must be mounted in a container that is adequate to prevent piston exten- sion. 1. Using air or nitrogen, pressurize suspension to 1100 ±200 psi (7585 ±1380 kPa) through the charging valve and maintain pressure for twenty (20) minutes minimum.
Page 321: Rear Suspension
REAR SUSPENSIONS Removal ® The HYDRAIR II suspensions are hydro-pneumatic components containing oil and nitrogen gas. The oil an gas in the four suspensions carry the gross truck TABLE 1. TOOL LIST FOR SUSPENSION PIN weight less wheels, spindles and final drive assem- REMOVAL bly.
Page 322 FIGURE 3-2. NITROGEN CHARGING VALVE 1. Valve Cap 6. Valve Body 2. Seal 7. O-Ring 3. Valve Core 8. Valve Stem 4. Swivel Nut 9. O-Ring FIGURE 3-3. SUSPENSION MOUNTING PIN 5. Rubber Washer (Typical, Top and Bottom) 1. Pin 6.
Page 323: Installation
Installation 1. Inspect mounting bore sleeves (9, Figure 3-3) and bearing spacers for damage or wear. Check fit of pins in bores prior to installing sus- pension. 2. Secure suspension to fork lift and raise into posi- tion. (Suspension assembly should be retracted as far as possible prior to installation.) 3.
Page 324 H3-4 Rear Suspensions 4/03 H03015...
Page 325: Disassembly
1. Remove charging valve guard and cover over pressure sensor. NOTE: If other repairs are necessary, refer to your local Komatsu Distributor for repair information and 2. Depress charging valve stem to insure all nitro- instructions not covered in this manual.
Page 326: Pressure Test
3. Install the wiper seal (15, Figure 3-6), rod lip PRESSURE TEST seal (16), and buffer seal (17). When installing After rebuild is complete, suspension assembly backup rings with rod seal (16) and step seal should be tested for leakage. (17), be certain radius is positioned toward the seal and the white dot is positioned away from the seal as shown in Figure 3-6.
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Page 335 SECTION J BRAKE CIRCUIT INDEX BRAKE CIRCUIT..............J2-1 Service Brake Circuit Operation .
Page 336 ROCKWELL ARMATURE SPEED REAR DISC BRAKES ........J6-1 Rear Brakes .
Page 337: Brake Circuit
Outlined below are the functions that are necessary for In the 830E truck, there are two independent means safe truck operation: of brake actuation, the service brake pedal and brake lock switch.
Page 338 FIGURE 2-1. HYDRAULIC BRAKE CABINET 1. Rear Brake Accumulator 11. BF & BR Test Port 19. Automatic Apply Valve 2. Charging Valve (Front & Rear Brake) 20. Bleed Down Valve 3. Front Brake Accumulator 12. Stop Light Switch (Rear Brake Accumulator) 4.
Page 339: Secondary Braking And Automatic Apply
SECONDARY BRAKING AND Normal Operation (key switch on, engine running) AUTOMATIC APPLY • Parking brake switch "ON" The parking brake solenoid (16) is de-energized. A fundamental function of the brake system is to The oil pressure in the parking brake lines return provide reserve braking in the event of any single to tank and the springs in the parking brake will failure.
Page 340: Brake Lock Circuit
BRAKE LOCK CIRCUIT By turning on the dash mounted toggle switch, a The primary function of the brake lock is to provide a solenoid valve (15, Figure 2-1) and pressure reducing means for the operator to hold the vehicle while at the valve (PR2, 14) will apply unmodulated pressure oil at shovel or dump.
Page 341 FIGURE 2-2. BRAKE VALVE (FULL CUT-AWAY) 1. Actuator Cap 2. Adjustment Collar 3. Actuator Base 4. Actuator Plunger 5. Wiper Seal 6. Poly-Pak Seal Assembly 7. Valve Body 8. Glyde Ring Assembly 9. Plunger Return Spring 10. Regulator Springs (B1) 11.
Page 342 FIGURE 2-3. BRAKE VALVE (PARTIAL CUT-AWAY) 1. Actuator Base 2. Brake Valve 3. Orfice Set-Screw J2-6 Brake Circuit J02032...
Page 343: Brake Circuit Component Service
BRAKE CIRCUIT COMPONENT SERVICE BRAKE VALVE The Brake Valve is a pressure modulating valve, actu- ated mechanically (brake pedal) or hydraulically through the automatic apply valve (11, Figure 3-1). The Brake Valve independently controls the pressure delivered to the front and rear service brake assem- blies.
Page 344 4. Tag and remove all hydraulic lines from brake valve. Plug lines and ports to prevent possible contamination. Remove all valve fittings. Discon- nect wiring harness at differential pressure switch Before disabling brake circuit, be sure truck connector. wheels are blocked to prevent possible roll-away. 5.
Page 345: Installation
Installation 1. Move the brake valve assembly into position and 5. Close both accumulator bleed down valves after secure in place with capscrews and lockwashers. precharge is complete. Tighten capscrews to standard torque. NOTE: To prevent excess oil from coming in contact 2.
Page 346: Disassembly
6. Start the engine and bleed air from brake lines and 2. Drain all oil from all ports of the valve by rotating brakes. Actuate the brake lock switch and open the valve over a suitable container. the uppermost bleeder screw on all rear brake 3.
Page 347 FIGURE 3-5. BRAKE VALVE 1. Adjustment Collar 9. Back-up Ring 17. Reactio Plunger (B2) 25. O-Ring 2.Actuator Plunger 10. O-Ring 18. Wiper Seal 26. Retaining Plug 3. Glyde Ring Assembly 11. Back-up Ring 19. Back-up Ring 27. Base Plate 4. Plunger Return Spring 12.
Page 348: Cleaning And Inspection
NOTE: Throughout the following steps, it is important 4. Inspect each spring carefully for cracks or breaks. to keep the circuits and circuit components identified Any spring with a crack or break must be re- as to which side of the unit they came from. For a given placed.
Page 349 FIGURE 3-7. SLEEVE SEAL PLACEMENT 1. Back-Up Ring 4. Back-Up Ring 2. O-Ring 5. O-Ring 3. Regulator Sleeve 6. O-Ring FIGURE 3-6. VALVE BODY SEAL INSTALLATION Regulator Sleeve O-Ring Installation 1. Actuator Plunger 4. Back-Up Ring 1. Install an O-ring (2, Figure 3-7) onto the smallest 2.
Page 350 Assembly of Valve NOTE: Start with either side (circuit) of the valve and NOTE: Check to insure that the spool will slide build that side complete through Step 4 before starting smoothly and freely. Replace the entire sleeve assem- on the other side (circuit). Be careful to assemble bly and spool, if the spool does not slide smoothly and components into the circuit from which they were freely.
Page 351: Differential Pressure Switch
DIFFERENTIAL PRESSURE SWITCH NOTE : In the following assembly, make a note of the color (red or green) of spring (8). The spring color will The differential pressure switch (1, Figure 3-9) determine final adjustment of the switch. Refer to mounted on the brake valve detects an imbalance in Table I, "Differential Pressure Switch Adjustment".
Page 352: Valve Bench Test And Adjustment
VALVE BENCH TEST AND ADJUSTMENT • Hose fittings for valve ports: The following parts and test equipment will be required Port PX is 7/16 in. – 4 SAE. to completely bench test and adjust the dual control Ports P1, P2, B1 and B2 are 3/4 in. – 8 SAE. treadle valve.
Page 353 Test Set Up Procedure 3. Gradually apply pressure on each circuit (one at a time) to check for leaks around the plunger. 1. Position the valve in the fixture to allow plungers Make sure the adjustment collar is screwed all the to be activated by hand using a lever (refer to way down on the threads.
Page 354: Installation Of Brake Pedal Actuator To Brake Valve
Rear Brake - “B1” (“BR” on truck): 2000 ±80 13. Insert pry bar under pivot pin to actuate the “B2” psi (13 790 ±552 kPa) section of valve. Front Brake - “B2” (“BF” on truck): 3000 ±150 14. Slowly depress the plunger while observing the psi (20 685 ±1034 kPa) ohmmeter;...
Page 355 Installation Of Brake Pedal Actuator Assembly to Brake Valve 1. Install jam nut (9, Figure 3-11) and set screw (10) Be sure to install spring assembly correctly, with to brake pedal actuator (7). larger ball socket end pointing to the pedal struc- 2.
Page 356 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL 1. Install nylon bearings (7, Figure 3-12) in retard (Dual Function Pedal) pedal. 2. Install retard pedal (16) to brake pedal actuator Installation of Retard Pedal To Brake Pedal (17) with pivot shaft (8). Install two retainer clips (6).
Page 357: Hydraulic Brake Accumulators
HYDRAULIC BRAKE ACCUMULATORS There are two hydraulic brake accumulators located on the brake manifold in the brake control cabinet behind the operator’s cab. The larger accumulator [2.5 gal. (9.51 l) capacity] supplies the pressure necessary for actuation of the front service brakes. The small accumulator [1 gal.
Page 358 FIGURE 3-17. PLUG AND POPPET REMOVAL 9. With wrench on valve stem flats, remove the nut from the valve stem. 10. Insert hand into shell fluid opening. Depress bag FIGURE 3-14. LOCKNUT REMOVAL and eliminate as much gas pressure as possible. 11.
Page 359 Assembly 9. Install anti-extrusion ring inside shell. Fold anti-ex- trusion ring to enable insertion into shell. Place 1. Replace shell in vise, if removed. anti-extrusion ring on plug and poppet assembly 2. Pour a liberal amount of clean C-4 hydraulic oil with its steel collar toward shell mouth.
Page 360 14. Install O-ring over plug and poppet assembly and Charging Procedure push until seated. 1. Mount hose assembly gland nut on pressure regulator. DO NOT TWIST O-RING. Pure dry nitrogen is the only gas approved for use 15. Install spacer with smaller diameter of the shoulder in brake accumulators.
Page 361 BRAKE CIRCUIT CHECK-OUT PROCEDURE The brake circuit hydraulic pressure is supplied from NOTE: If internal leakage within the steering circuit the steering circuit at the bleed down manifold. is excessive, this also may contribute to problems Some brake system problems, such as spongy within the brake circuit.
Page 362 The steering circuit can be isolated from the brake The steering accumulator can be bled down with circuit by removing the brake supply line from the engine shut down, turning key switch "Off", and bottom side of the bleeddown manifold (refer to waiting 90 seconds.
Page 363 EQUIPMENT REQUIRED BRAKE CIRCUIT ABBREVIATIONS Automatic Apply Pressure Included on the last page of this module is a data sheet to record the information observed during the Accumulator, Front Brake hydraulic brake system check-out procedure. The Supply Pressure to Dual Controller for data sheet can be removed, copied, and used during Front Brakes the check-out procedure.
Page 364: Parking Brake
INITIAL SYSTEM SET-UP PARKING BRAKE Prior to checking the brake system, the hydraulic NOTE: Move one of the pressure measuring steering system must have proper accumulator pre- instruments from the BF or BR locations to the PK2 charge and be up to normal operating temperatures. test port above the Park Brake Solenoid.
Page 365 14. Release pedal, assure that each circuit's pres- 22. Start engine to recharge hydraulic system. Allow sure is zero. engine to run until low brake accumulator pres- sure stabilizes at or above 3200 psi (22,064 · Record on data sheet. kPa).
Page 366 30. Depress the brake pedal very slowly until the 34. Turn key switch off and bleed down both brake brake differential pressure switch activates the accumulators by opening the manual bleed low brake pressure lamp and buzzer. down valves on the brake manifold. 35.
Page 367 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: The Brakes are Locked, Service and/or Parking Parking brake solenoid is de-energized. Check power to solenoid Connections to tank and pressure ports reversed. Correct the plumbing. Parking brake solenoid coil defective. Replace coil.
Page 368 TROUBLE: Differential Pressure Warning Circuit activates Briefly When Brakes are Applied or Released Brake valve out of balance (not tracking). Adjust collars according to instructions. Differential pressure switch is defective or is improp- Check the switch and replace if necessary. Check erly adjusted.
Page 369 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Low Pressure Warning is On Even Though System Pressure is Proper Short in electrical system. Check wiring. Pressure switch is defective. Replace the switch. TROUBLE: Low Pressure Warning Comes On and Pressure is Low Steering circuit is malfunctioning.
Page 370 NOTES J4-10 Brake Circuit Check-Out Procedure J04031...
Page 371 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET MACHINE MODEL_______UNIT NUMBER_________SERIAL NUMBER________________ Initial System Set-up Operate Hydraulic Steering System to obtain proper operating temperature. Refer to Check-out Procedures. STEP 2 _______________ Brake Accumulators charged to 1400 psi (9.65 MPa). STEP 6 _______________ Auto apply brake release pressure.
Page 372: Brake Circuit Checkout Procedure
KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET Brake Lock/Secondary System STEP 17 _______________ Rear brake pressure when brake lock is applied. _______________ Low Brake Pressure and Auto Apply STEP 19 _______________ LAP pressure after 2 minutes. STEP 20 _______________ LAP pressure when low brake pressure fault occurs.
Page 373: Rockwell Wheel Speed Front Disc Brakes
ROCKWELL WHEEL SPEED FRONT DISC BRAKES BRAKE CALIPER Caliper Removal 1. Remove front tires and rims according to proce- Each front wheel speed brake assembly has three* dure in Section “G”. calipers on one disc. Each caliper has six pistons and two linings (three apply pistons and one lining for 2.
Page 374 Installation Prior to brake caliper installation, refer to “Brake Lin- ing” for wear limits regarding brake linings and brake discs. If linings and/or disc is worn beyond accept- able limits, replace the parts at this time. 1. After repair, cleaning and inspection of the brake caliper, install each brake component to its original location.
Page 375 1. Housing 2. Bleeder 3. Crossover Tube 4. T-Fitting 5. Elbow Fitting 6. Retainer Bolt 7. End Cap 8. End Cap 9. Brake Lining 10. Piston Dust Shield 11. Piston 12. Piston O-Ring Seal 13. Backup Ring 14. Brake Mounting Bolt 15.
Page 376 Cleaning and Inspection NOTE: All seals (12, Figure 5-3) should be replaced at assembly. 1. Preliminary cleaning can be more effective if 6. Inspect piston (11) surfaces for scratches, linings are first removed. However, retaining excessive wear, nicks, and general surface fin- plates should be temporarily reinstalled in order ish deterioration that can contribute to seal to stay with brake assembly through overhaul...
Page 377: Brake Lining
NOTE: These bolts are highly stressed and should must be replaced. This will require disassembly be replaced whenever their condition appears of the caliper. questionable. A 3/4-16 UNF-28 tap lubricated with a 6. Inspect end plates for wear. Replace if grooves light oil may be used to inspect tapped holes in will not allow lining back plate to slide freely.
Page 378 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE Front Brake Conditioning After any brake lining replacement, or at new truck start up, the brake linings and discs must be bur- 1. To prevent overheating and possible destruc- nished. A surface pyrometer will be necessary to tion of rear brakes, temporarily disconnect the accurately record disc temperature during brake bur- REAR brakes while burnishing front wheel...
Page 379: Brake Bleeding Procedure
BRAKE BLEEDING PROCEDURES Attach brake lines and bleed brake calipers accord- ing to the following instructions. 1. Fill hydraulic tank following procedure in Sec- tion “P”, Hydraulic Tank Service. 2. Close brake accumulator drain valves (7, Figure 5-5), if open. 3.
Page 380 NOTES J5-8 Rockwell Wheel Speed Front Disc Brakes J05019...
Page 381: Rockwell Armature Speed Rear Disc Brakes
ROCKWELL ARMATURE SPEED REAR DISC BRAKES REAR BRAKES CALIPER, DISC, AND PARKING BRAKE Each rear wheel service brake assembly consists of two discs, each with a four piston caliper and a lining on each side of the disc. Both discs are attached by adapters to the wheel motor armature.
Page 382 Caliper, Disc, And Parking Brake Installation 1. If removed, install adapter (2, Figure 6-3) and secure in place with capscrews and flatwashers (1). Tighten capscrews to standard torque. 2. Install adapter (9) on armature shaft drive (20) and secure in place with capscrews and flatwash- ers (7).
Page 383 24. Remove studs and install outer caliper half (5) and SHIM PACK CHART secure in place with capscrews and flatwashers (4). Tighten capscrews to standard torque. Shim Pack 0.010 in. 0.040 in. Required (in.) Shim Qty. Shim Qty. 0.000 – 0.005 0.005 –...
Page 384 25. Install linings (Refer to “Lining Replacement”). 27. Install park brake caliper, refer to “Park Brake Cal- iper Installation”. 26. Install bleeders in both calipers. Install crossover tubes and brake lines. 28. Brakes must be bled and burnished before truck is returned to production.
Page 385 Caliper, Disc, And Parking Brake Installation 14. Install outer disc adapter (10). Install capscrews and flat washers (9). Tighten 12 point head cap- 1. If removed, install adapter (2, Figure 6-3A) and screws (9) to standard torque. secure in place with capscrews and flatwashers (3).
Page 386 CALIPER PISTON Piston Assembly Removal 1. Position brake caliper so that return pin nut (1) is in an upright position. (Refer to Figure 6-7). 2. Hold return pin (10) in place with a narrow bladed screwdriver or hex key wrench and remove nut (1).
Page 387 NOTE: If desired, installation of brake housing 1. The piston subassembly can be inspected for components may be temporarily withheld to perform a required return spring force and built-in clearance “Functional Test”. adjustment at the same time. Use the set-up on a spring checker as shown in Figure 6-8.
Page 388 8. Return spring force indication, Step 6, should be a minimum of 180 lbs. (808 N) when fully com- pressed in the piston subassembly. Although suf- ficient force will still exist to return the piston when force is as low as 135-140 lbs. (606- 628 N), and under emergency conditions may con- tinue to be used, it is recommended that the pis- ton assembly be disassembled and the spring...
Page 389 3. Return pin should be placed in extended position when assembling into brake caliper for a special pin retraction tool (Figure 6-10) or equivalent, is required for this. Insert piston assembly in tool and secure firmly with knurled nut. Place pin return tool/piston assembly combination on arbor press table, drop in 3 dowel pins as indicated, place spring pod tool on top of dowels, apply...
Page 390 Grip assemblies and return pins are critical items in the operation of the piston return mechanism and should not be mishandled. Under no circum- stances should pin diameter be clamped in a vise or gripped with pliers. In normal use, surface of pin will show only a very slow rate of wear and both pins and grips will normally last through many brake lining changes and brake overhauls.
Page 391 2. Measure spring force at maximum service deflec- Disassembly of Piston Assembly tion on a spring checker. Use the outer spring To disassemble piston assembly for separate inspec- guide (8, Figure 6-7) for test setup purposes, as tion of return spring (14, Figure 6-7), return pin and grip shown in Figure 6-12.
Page 392: Bench Test
Assembly of Piston Assembly 5. Continue holding spring compression and turn retaining ring one full turn (minimum) counter- 1. Assemble inner spring guide (10, Figure 6-15), clockwise, plus any additional amount (1/8 turn return pin and grip assembly (8 & 9) and spring max.) to allow for lockwire installation.
Page 393: Brake Lining
Brake Circuit on the mum of 0.31 in. (7.8 mm). Use of linings beyond this Komatsu truck. wear limit will result in a decrease of braking action, 4. Attach hydraulic source to inlet port of caliper and possible damage to disc.
Page 394 FIGURE 6-17. PISTON RETRACTION TOOL 3. Inspect condition of brake caliper thoroughly 4. Inspect discs for wear (Figure 6-18). Place a before installing linings. straight edge across face of disc and measure from straight edge to worn face. It is recom- a.
Page 395 5. Install new linings and lining retaining plate (2, Figure 6-16). ® 6. Apply Loctite 271 to threads of capscrews (1) and tighten to 190 ft.lbs. (258 N.m) torque. Check that linings slide freely between retainer plates. 7. Check brakes for operation. Linings should be free after release, with minimum of 0.03 in.
Page 396 • BEFORE DISCONNECTING PRESSURE LINES, are installed, or before a new Komatsu Truck is put into REPLACING COMPONENTS IN THE HYDRAU- operational service. A surface pyrometer is required to...
Page 397 Rear Brake Conditioning 5. If linings smoke or smell during the second cycle, continue to repeat burnishing cycle until smoke Note: Front brakes will require burnishing and smell are gone or are significantly reduced. independently from rear brakes in order to control disc temperatures.
Page 398: Brake Bleeding Procedure
BRAKE BLEEDING PROCEDURE 6. Check hydraulic reservoir level as bleeding takes Attach brake lines and bleed brake calipers according place, maintain correct level. to the following instructions: 7. Before returning truck to production, brake lining 1. Fill hydraulic tank following procedure in Section must be burnished.
Page 399: Rockwell Disc Parking Brake
ROCKWELL DISC PARKING BRAKE PARK BRAKE CALIPER A park brake assembly is mounted to each wheel motor on each outboard disc and is intended for Removal parking only. The park brake caliper is a dual piston, spring applied, hydraulically released type brake The park brake caliper may be removed from wheel designed for petroleum base fluid.
Page 400: Installation
Installation Parking Brake Adjustment Do not start truck engine until both parking brake Do not start the truck engine until the parking assemblies have been installed, adjusted, and all brake has been installed, adjusted, and the hydraulic brake lines are tightly connected. hydraulic brake lines are tightly connected.
Page 401 Exceeding MAXIMUM pressure of 3000 psi (20.7 MPa) may rupture seals in park brake caliper and cause leakage. 13. Tighten clamp capscrew (3) to 125 ft.lbs. (170 N.m) torque and insure parking brake lines are tightly connected. Lockwire clamp capscrew (3) to adjusting bolt (16) as shown to prevent loos- ening.
Page 402: Park Brake Caliper Disassembly
Park Brake Caliper Disassembly Cleaning and Inspection NOTE: To assure that tension on springs (9, Figure 7-2) has been released, be certain that jam nut (17) has been loosened on adjustment bolt (16) and that clamping capscrew (3) has been loosened one turn. Be sure that adjustment bolt (16) has been loosened Petroleum base cleaning solvents are flammable.
Page 403: Park Brake Caliper Assembly
5. Inspect housing cylinder walls for damage. Park Brake Caliper Assembly Scratches or corrosion to a depth of 0.002 in. 1. Using all new seal assemblies, lubricate seals (0.005 cm) or less on the cylinder wall can be (6 & 12, Figure 7-2) with clean hydraulic oil as blended out with 300-500 grit wet-or dry sand- used in brake circuit.
Page 404: Park Brake Lining
PARK BRAKE LINING REPLACEMENT BRAKE BLEEDING PROCEDURE 1. Bleed parking brake after starting engine. Inspect park brake linings periodically for wear. Lin- ings must be replaced before lining material has 2. Move parking brake switch on instrument panel been worn to the top of the retaining screws. Use of to “Off”...
Page 405 SECTION L HYDRAULIC SYSTEM INDEX HYDRAULIC SYSTEM ............. .L2-1 COMPONENT DESCRIPTION .
Page 406 HOIST CIRCUIT ..............L7-1 HOIST CIRCUIT OPERATION .
Page 407: Hydraulic System
HYDRAULIC SYSTEM HYDRAULIC SYSTEM OPERATION The service capacity of the tank is 238 gal. (901 l). The following describes the basic hydraulic system Type C-4 hydraulic oil is recommended for use in operation. Further system description is outlined the hydraulic system. under different system circuits such as the hoist cir- cuit and steering circuit in this section of the manual.
Page 408: Component Description
cuit filters (4, Figure 2-1) are located on the right side, behind the fuel tank. Flow restriction through the filter element is sensed by a pressure differential switch. When restriction is excessive, the switch will turn on an indicator lamp When servicing the hydraulic system, relieve inside the cab to notify the operator that filter service pressure before disconnecting hydraulic and...
Page 409 FIGURE 2-2. STEERING CIRCUIT COMPONENTS (VIEWED FROM BELOW TRUCK) 1. Hydraulic Tank 5. Hoist Circuit Pump 9. Steering Accumulators 2. Hoist Cylinders 6. Bleeddown Manifold 10. Steering Quick Disconnects 3. Steering / Brake Pump 7. Flow Amplifier 11. Brake Quick Disconnects 4.
Page 410 NOTES L2-4 Hydraulic System L02027...
Page 411: Hydraulic System Component Repair
HYDRAULIC SYSTEM COMPONENT REPAIR HOIST PUMP Removal 2. Drain the hydraulic tank by use of the drain NOTE: It is not necessary to remove the steering valve (12, Figure 3-1) located on the bottom of pump with the hoist pump. The steering pump may the tank.
Page 412 4. Disconnect and remove the hose at the alterna- Installation tor end and swing clear of work area. NOTE: The following procedure assumes the 5. Close the shut-off valves (2 & 10, Figure 3-1). steering pump is already in position on the truck. 1.
Page 413 FIGURE 3-2. STEERING PUMP REMOVAL 1. Hoist Pump 7. O-Ring 13. Inlet Port 2. Nut & Washer 8. Transition Plate 14. Compensator Adjuster 3. Dowel 9. Coupling 15. Plug 4. O-Ring 10. Capscrew 16. O-Ring 5. Capscrew 11. Steering & Brake Pump 17.
Page 414 FIGURE 3-3. HOIST PUMP DISASSEMBLY 1. O-Ring 7. Stud 13.Bearings 19.Pressure Plate 2. Bearing Plate 8. O-Ring 14.Steel Ring 20.Dowels 3. O-Ring 9. Connector Plate 15.Backup Ring 21.Coupling 4. O-Ring 10.Steel Ring 16.O-Ring & Retainer 22.Snap Ring 5. Gear Plate 11.Idler Gear 17.Isolation Plate 23.O-Ring...
Page 415 1. Drive Gear & Shaft 2. Seal 3. Idler Gear 4. Steel Ball 5. Flange 6. Dowel 7. Gear Plate 8. O-Ring 9. O-Ring 10. Bearing Plate 11. O-Ring 12. Thru Studs 13. Steel Rings 14. Backup Ring 15. O-Ring & Retainer 16.
Page 416 INSPECTION OF PARTS 1. Examine the gear bores in both gear plates, ref- erence Figure 3-7. During the initial break-in, the gears cut into the gear plates. The nominal depth of this cut is 0.008 in (0.203 mm) and should not exceed 0.015 in (0.381 mm). As the gear teeth cut into the gear plates, metal is rolled against the pressure plates.
Page 417 Assembly 1. A suitable seal press ring or plug and two small wood blocks should be available. 2. The following seal installation procedures are outlined for use with a vise, but they can be adapted for use with a press if one is available. 3.
Page 418 FIGURE 3-11. PRESSURE PLATE INSTALLATION 1. Gear Plate 3. Slot 2. Pressure Plate FIGURE 3-10. PUMP REASSEMBLY NOTE: To ensure the gear pump is correctly timed 1. Gear Plate 7. O-Ring during reassembly, place a mark on the end of the 2.
Page 419 FIGURE 3-13. HOIST PUMP REASSEMBLY 1. Drive Gear and Shaft 5. O-Ring 9. Coupling 13. O-Ring & Retainer 2. Idler Gear 6. Connector Plate 10. Thru Studs 14. Dowel 3. Gear Plate 7. O-Ring 11. Steel Ring 15. Isolation Plate 4.
Page 420 FIGURE 3-14. HOIST PUMP REASSEMBLY 1. Drive Gear (Rear) 8. O-RIng 14. Capscrew 20. Nut 2. Dowel 9. O-Ring 15. Bearing Plate 21. O-Ring 3. O-Ring 10. Gear Plate 16. Transition Plate 22. Dowel 4. O-Ring 11. Connector Plate 17. O-Ring 23.
Page 421 28. Using an 18 inch (45 cm) adjustable wrench, check pump drive shaft rotation. The drive shaft will be tight but should turn freely with a maxi- mum of 5 to 10 ft lbs (7 to 14 N.m) torque, after the initial surge.
Page 422 HYDRAULIC TANK 5. Continue to repeat steps 1 thru 4 until oil level is maintained in the top sight gauge with the Filling Instructions engine stopped, key switch “Off”, and body down. NOTE: If filling is required, use only type C-4 hydraulic oil as specified on the truck Lubrication NOTE: With engine running and oil at operating Chart.
Page 423: Hydraulic Tank Strainers
Installation 1. Install hydraulic tank and secure mount caps with capscrews and lockwashers. Tighten to 454 ft. lbs. (615 N.m) torque. 2. Uncap hydraulic lines and attach to the proper connections. 3. Replace breather filters if required. 4. Fill the hydraulic tank with clean, filtered C-4 hydraulic oil.
Page 424: Hoist Circuit Filters
HYDRAULIC TANK BREATHERS There are two breather filters (3, Figure 3-16) located on top of the hydraulic tank to allow air in and out of the tank. The filters should be replaced at the interval specified on the lubrication chart. Keep the area around the breather filters clean and free of debris build up.
Page 425 FILTER ELEMENT REPLACEMENT INDICATOR SWITCH The indicator switch (5, Figure 3-18) is factory preset to actuate at 35 psi (241 kPa). When activated, the switch will illuminate the amber “Hydraulic Oil Filter” warning lamp located on the overhead display panel in the operator’s cab.
Page 426 NOTES L3-16 Hydraulic Component Repair 7/02 L03026...
Page 427: Steering Circuit
STEERING CIRCUIT STEERING CIRCUIT OPERATION The accumulator oil is supplied constantly to the The steering/brake pump (2, Figure 4-1) delivers oil flow amplifier, via the bleed down manifold. The to the high pressure steering filter (7), then to a accumulators also act as a reservoir for pressurized bleed down manifold valve (4) which is located on hydraulic oil to be used during an emergency situa- the inside left frame rail.
Page 428: Component Description
COMPONENT DESCRIPTION Hydraulic oil flows to the closed center steering valve STEERING CONTROL UNIT via the flow amplifier. The flow amplifier is pilot-con- The steering control unit is located behind an access trolled by the steering valve. Due to large oil dis- cover on the front of the operator's cab.
Page 429 FIGURE 4-2. FLOW AMPLIFIER L04037 Steering Circuit L4-3...
Page 430 No Steer (Refer to Figure 4-3): High pressure oil from the steering pump and steer- As pressure builds up in these two areas, oil passes ing accumulators is available through the steering through orifices in the end of the priority valve and bleeddown manifold to the HP port on the flow ampli- builds pressure on the end of the valve and port PP.
Page 431 FIGURE 4-3. FLOW AMPLIFIER (No Steer) L04037 Steering Circuit L4-5...
Page 432 Steering Left (Refer to Figure 4-4): When the operator turns the steering wheel “left”, the The number of holes K (9) in sleeve E determine the steering control unit valve is opened to allow oil com- amount of additional oil that is added to the steering ing in port P to pass to the gerotor section of the con- control unit oil passing through hole G.
Page 433 FIGURE 4-4. FLOW AMPLIFIER (Steering Left) L04037 Steering Circuit L4-7...
Page 434 Steering Right (Refer to Figure 4-5): Only a few differences occur between steer left and The combined oil from the amplifier valve passes steer right. When the operator turns the steering through the center area Q of the directional valve to wheel right, oil is supplied out ports R and LS of the port CR where it goes to the opposite ends of the steering control unit.
Page 435 FIGURE 4-5. FLOW AMPLIFIER (Steering Right) L04037 Steering Circuit L4-9...
Page 436 No Steer, External Shock Load (Refer to Figure 4-6): When the operator is not turning the steering wheel, As the cylinders are allowed to move, the other ends the steering control unit valve supply is closed. The will have less than atmospheric pressure on port CL. directional valve remains centered by its springs thus This low pressure permits oil that is escaping through closing the passages to ports CL and CR.
Page 437 FIGURE 4-6. FLOW AMPLIFIER (No Steer, External Shock Load) L04037 Steering Circuit L4-11...
Page 438: Bleed Down Manifold
BLEED DOWN MANIFOLD The bleed down manifold (10, Figure 4-7) is located The relief valves, accumulator bleed down sole- on the inside of the left hand frame rail just behind noids, and steering pressure switch are not individu- the flow amplifier (6). ally rebuildable and are factory preset.
Page 439: Accumulators
ACCUMULATORS HIGH PRESSURE FILTER The accumulators (6, Figure 4-1) are a bladder type. The high pressure filter (1, Figure 4-1) filters oil for The accumulators are charged to 1400 psi (9.7 MPa) the steering and brake circuits. with pure dry nitrogen. If the filter element becomes restricted, a warning Oil entering the accumulator pushes the bladder indicator located in the cab, on the overhead display...
Page 440 Operation Refer to the parts list at right and the pump illustra- FIGURE 4-9. CUT-AWAY VIEW OF tion in Figure 4-9 for the following description of oper- STEERING PUMP ation. 1. Plug 30. Back-Up Ring • The driveshaft (38, Figure 4-9) runs through the 2.
Page 441 FIGURE 4-9. CUT-AWAY VIEW OF STEERING PUMP L04037 Steering Circuit L4-15...
Page 442 PRINCIPLE OF OPERATION Full Pump Volume: Control piston (1, Figure 4-10) controls the angle of the swashblock (4). When the control piston moves to the full right position, the pump is at maximum pumping capacity. The driveshaft turns the splined housing (2) which contains the pumping pistons (3).
Page 443 Neutral Position: Neutral position (Figure 4-12) results when the con- trol piston (1) centers the swashblock (4). The swashblock angle is now zero and swashblock face is now parallel to cylinder face. Therefore, no inward or outward motion of the pump pistons exists as pis- ton shoes rotate around the swashblock face.
Page 444 NOTES L4-18 Steering Circuit L04037...
Page 445: Steering Circuit Component Repair
STEERING CIRCUIT COMPONENT REPAIR BLEED DOWN MANIFOLD Removal NOTE: The Bleed Down Manifold may not have to be removed from the truck to replace components. If problem area has been isolated simply remove defective components and replace with new. Relieve pressure before disconnecting hydraulic and other lines.
Page 446: Accumulator
ACCUMULATOR Removal Relieve pressure before disconnecting hydraulic and other lines. Tighten all connections before applying pressure. Hydraulic fluid escaping under pressure can have sufficient force to enter a person's body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.
Page 447 Disassembly 1. Once the accumulator has been removed from the equipment, the accumulator body should be secured in a vise, preferably a chain vise. If a standard jaw vise is used, brass inserts should be used to protect the hydraulic port assembly from damage.
Page 448 1. After shell (4, Figure 5-5) has been cleaned and der or damage new seals. If this area is pitted inspected, place accumulator shell in vise or on consult your Komatsu Service Manager. table. 2. Thoroughly coat the inside of the accumulator shell with a liberal amount of clean hydraulic oil to lubricate and cushion the bladder.
Page 449 7. Hold bladder valve stem on the flats with a 19. Precharge accumulator to 100 - 120 psi (690 - wrench and tighten nut (5) securely. 827 kPa). Refer to “Steering Accumulator Charging Procedure” for details. After precharg- 8. If removed, install pressure switch (15), valve ing, install plastic cover over hydraulic port to assembly (11) and charging valve onto gas prevent contamination.
Page 450: Steering Accumulator Charging Procedure
10. Connect a hydraulic power supply to the oil port NOTE: If one accumulator is low on nitrogen, it is on the accumulator. Be sure bleed plug (12, recommended that both accumulators be checked/ Figure 5-5) is installed. charged at the same time. 11.
Page 451: Flow Amplifier
NOTE: When charging the accumulators, allow 10. Operate truck and check steering for normal adequate time for the system to fully charge and for operation. the nitrogen gas temperature to stabilize (10-15 minutes). 6. Shut off charging kit and check pressure gauge reading.
Page 452 Disassembly FIGURE 5-7. FLOW AMPLIFIER VALVE NOTE: The flow amplifier valve is a precision unit 1. Capscrew manufactured close tolerances, therefore 2. Lockwasher complete cleanliness is a must when handling the 3. Capscrews flow amplifier valve. Work in a clean area and use lint 4.
Page 453 FIGURE 5-7 FLOW AMPLIFIER VALVE L05026 Steering Component Repair L5-9...
Page 454 FIGURE 5-7. SHOCK AND SUCTION VALVE FIGURE 5-8. AMPLIFIER SPOOL ASSEMBLY ASSEMBLY 1. O-Ring 3. O-Ring 1. Check Valve 7. Retaining Ring 2. Pilot Section 2. O-Ring 8. Inner Spool 3. Spool 9. Spring 4. Pin 10. Plug 5. Pin 11.
Page 455 Reassembly 8. Install spring control (31), springs (32 & 33) and 1. Thoroughly lubricate each part prior to installa- spring stop (34). tion using clean, type C-4 hydraulic oil. 9. Lubricate O-rings (6, 7 & 8) with molycote 2. Reassemble the Amplifier spool assembly in grease and position on cover (5).
Page 456: Steering Control Unit
STEERING CONTROL UNIT Removal Relieve pressure before disconnecting hydraulic and other lines. Tighten all connections before applying pressure. Hydraulic fluid escaping under pressure can have sufficient force to enter a person's body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.
Page 457 3. Remove end cover capscrews and washers. Remove capscrew with rolled pin (3, Figure 5-11). Mark hole location of capscrew with rolled pin on end cover to facilitate reassembly. After servicing the steering control unit, hydrau- 4. Remove end cover (4) and O-ring (2, Figure 5- lic steering lines should be checked for correct 12).
Page 458 Assembly NOTE: When assembling the spool and sleeve, only one of the two possible matching positions of the spring slots can be used. The reason is that in the other end of the sleeve and spool (opposite end of the spring slots) there are three slots in the spool and three holes in the sleeve.
Page 459 FIGURE 5-14. NEUTRAL POSITION SPRING INSTALLATION 6. With neutral position springs (7, Figure 5-16) 7. Place the dust seal (1, Figure 5-18) in position. centered in spool and sleeve, install ring (3), Using a flat iron block over the seal, tap into rear bearing race (4), thrust bearing (5) and position.
Page 460 FIGURE 5-17. STEERING CONTROL UNIT 1. Dust Seal 7. Bearing Assembly 12. Spacer 18. O-Ring 2. Housing & Spools 8. Ring 13. Tube 19. End Cover 3. Ball 9. Pin 14. O-Ring 20. Washers 4. Threaded Bushing 10. Neutral Position 15.
Page 461 10. Install the check ball in the hole shown in Figure 11. Grease the housing O-ring (3) with Vaseline and 5-19. Install threaded bushing and lightly install in the housing groove. tighten. 12. Install the distribution plate (15, Figure 5-18) with plate holes matching the corresponding holes in the housing.
Page 462: Steering Cylinder
STEERING CYLINDER 3. Push rod (10) through top of gland, slowly advancing rod over rod seal and rod wiper. For steering cylinder removal and installation 4. Install new piston seal (4) and bearing (3) on procedure, refer to Section “G”. piston (5).
Page 463: Steering Circuit Filter
STEERING CIRCUIT FILTER The brake and steering circuit filter (Figure 5-21) is located on the right, inside frame rail, behind the fuel tank. The filter provides secondary filtering protection for hydraulic oil flowing to the bleeddown manifold valve for the steering and brake systems. An indicator switch (1) is designed to alert the opera- tor of filter restriction before actual bypass occurs.
Page 464 Removal INDICATOR SWITCH 1. With the key switch OFF, allow at least 90 sec- The indicator switch (1, Figure 5-21) is factory preset onds for the accumulators to bleed down. to actuate at 35 psid (241 kPa). When activated, the switch will illuminate the amber “Hydraulic Oil Filter”...
Page 465: Steering And Brake Pump
STEERING AND BRAKE PUMP 2. Drain the hydraulic tank by use of the drain located on the bottom side of the tank. Removal NOTE: Be prepared to contain approximately 238 NOTE: Clean the steering pump and surrounding gal. (901 L) of hydraulic oil.If the oil is to be reused, area carefully to help avoid contamination of clean containers must be used with a 3 micron hydraulic oil when lines are opened.
Page 466 NOTE: Use only Komatsu filter elements, or 17. Shut-off the engine and fully close both brake elements that meet the Komatsu hydraulic filtration accumulator needle valves in the brake cabinet.
Page 467 Disassembly Maximum volume stop gland (14, Figure 5-23) MUST be removed BEFORE further disassembly of control piston. When disassembling or assembling unit, choose 9. Without disturbing jam nut (16, Figure 5-23), a work area where no traces of dust, sand or unscrew gland (14) and remove stroke adjuster other abrasive particles which could damage the as a complete assembly.
Page 468 Rotating Group Driveshaft Group 27. Remove bearing retaining ring (3, Figure 5-23). Use a mallet on the tail shaft and tap driveshaft (1) out from the front of the pump housing. 28. Remove seal retainer (21) from pump housing. Rotating group weighs approximately 30 lbs. Use a mallet and tap saddle (20) out from the Extreme care must be taken not to damage cylin- inside of the pump housing.
Page 469 FIGURE 5-22. PUMP, FRONT HOUSING 1. Shaft 8. Name Plate 15. O-Ring 22. O-Ring 2. Bearing 9. Plug 16. Jam Nut 23. Plug 3. Snap Ring 10. O-Ring 17. Pin 24. Seal 4. Retainer Ring 11. Plate 18. O-Ring 25. Plug 5.
Page 470 FIGURE 5-23. PUMP, ROTATING GROUP 1. Springs 8. Pin 15. Washer 22. Roll Pin 2. Seal 9. Back-up Ring 16. Pin 23. Roll Pin 3. Piston Ring 10. Cylinder Barrel 17. Link 24. Saddle Bearing 4. Sleeve 11. Control Piston 18.
Page 471 9. Piston shoes must pivot smoothly, but end play b. Measure shoe thickness (the part held must not exceed 0.003 in (0.076 mm). between retainer (27, Figure 5-24) and cra- dle. All shoes must be equal within 0.0001in 10. Check end play as follows: (0.003 mm).
Page 472 ASSEMBLY Swashblock Group 11. Inspect swashblock (25, Figure 5-24) for The procedures for assembling the pump are basi- scratches, grooves, cracks or uneven surface. cally the reverse order of disassembly procedures. Replace if defective. During assembly, install new gaskets, seals, and O- rings.
Page 473 Rotating Group 4. Use a long brass bar and a mallet (or an arbor 16. Mating surfaces should be greased. Place cylin- press), to install saddle and bearing assembly der assembly on clean table with the valve plate into pump housing. Tap or press ONLY on the side down.
Page 474 Control Piston Group Valve Plate Group 25. Install piston rings (2 & 3, Figure 5-24) into their 34. Be sure driveshaft bearing (15, Figure 5-25) is in respective grooves on control piston (11) using place. Using assembly grease (to hold desired care to assure they are in proper location.
Page 475 45. Install O-rings (26, 27 and 28) in proper location 10. Install remaining plugs with new O-rings. on top of valve plate. Install compensator (13) 11. Install unloader module (29) on compensator to valve plate with capscrews (9) and tighten block with new O-rings (25) and socket head securely.
Page 476 NOTES L5-32 Steering Component Repair L05026...
Page 477: Hoist Circuit
HOIST CIRCUIT HOIST CIRCUIT OPERATION The hoist valve directs oil to the body hoist cylinders (1) for raising and lowering the dump body. Hoist The following hoist circuit operation description valve functions are controlled by the operator describes the basic hoist circuit. Details of individual through a flexible cable to the hoist pilot valve (6) in component operation is outlined under the individual the hydraulic component cabinet located behind the...
Page 478: Component Description
COMPONENT DESCRIPTION HIGH PRESSURE FILTERS HYDRAULIC TANK Hoist pump output flows to two remote mounted high pressure filters located on the lower inboard The hydraulic tank supplies hydraulic oil for the side of the fuel tank. The filter elements are rated at hoist, steering, and brake circuits.
Page 479 HOIST VALVE The hoist valve (Figure 7-3) is mounted above the hoist and steering pump. Hydraulic oil from the high pressure filters is routed to the hoist valve. The hoist valve is a split spool design. (The term “split spool” describes the spool section of the valve.) Separate spools control oil flow to each end of the cylinders.
Page 480 HOIST PILOT VALVE The hoist pilot valve (1, Figure 7-4) is located in the hydraulic component cabinet directly behind the operators cab. The hoist pilot valve spool is spring centered to the hold position. The valve is controlled directly by the operator through a lever and cable arrangement.
Page 481 FIGURE 7-5. COUNTERBALANCE VALVE SCHEMATIC The following pages describe hoist circuit operation in the float, power up, hold, and power down positions. (Refer to Figures 7-6 through 7-10.) L07027 Hoist Circuit L7-5...
Page 482 FLOAT POSITION OF PILOT VALVE AND FIGURE 7-6. HOIST CIRCUIT: FLOAT POSITION BODY ON FRAME (Figure 7-6) This is the condition while the truck is hauling. The 1. Hoist Relief Valve 2500 psi (17.2 MPa) Pilot Valve spool position is as shown in Figure 7-6; 2.
Page 483 FIGURE 7-6. FLOAT POSITION L07027 Hoist Circuit L7-7...
Page 484 POWER UP OPERATION (Figure 7-7) If the pressure exceeds 3000 psi (20.7 MPa) at port 23, the counterbalance valve will open again to direct The Hoist Pilot Valve spool is moved to the Power Up oil back to the hoist valve, preventing damage to the position when the operator moves the lever in the hoist cylinder seals from excessive pressure.
Page 485 FIGURE 7-7. POWER UP L07027 Hoist Circuit L7-9...
Page 486 HOLD OPERATION (Figure 7-8) FIGURE 7-8. HOIST CIRCUIT: HOLD POSITION The Pilot Valve spool is positioned to allow the pilot 1. Hoist Relief Valve 2500 psi (17.2 MPa) supply oil entering Port 12 to return to the tank 2. Flow Control Valve through Port 10.
Page 487 FIGURE 7-8. HOLD POSITION L07027 Hoist Circuit L7-11...
Page 488 FIGURE 7-9. HOIST CIRCUIT: POWER DOWN POWER DOWN OPERATION (Figure 7-9) POSITION When the operator moves the lever to lower the body, the Hoist Pilot Valve is positioned to direct the 1. Hoist Relief Valve 2500 psi (17.2 MPa) pilot supply oil in Ports 12 to Port 15 on the Hoist 2.
Page 489 FIGURE 7-9. POWER DOWN L07027 Hoist Circuit L7-13...
Page 490 FIGURE 7-10. HOIST CIRCUIT: FLOAT FLOAT OPERATION (Figure 7-10) POSITION When the operator releases the lever as the body 1. Hoist Relief Valve 2500 psi (17.2 MPa) travels down, The Hoist Pilot Valve spool returns to 2. Flow Control Valve the FLOAT position.
Page 491 FIGURE 7-10. FLOAT POSITION L07027 Hoist Circuit L7-15...
Page 492 NOTES L7-16 Hoist Circuit L07027...
Page 493: Hoist Valve
HOIST CIRCUIT COMPONENT REPAIR HOIST VALVE Removal 1. Shut down engine and turn keyswitch “Off”. 2. Thoroughly clean the exterior of the hoist valve. 3. Disconnect and cap or plug all line connections to help prevent hydraulic oil contamination, refer to Figure 8-1. Relieve pressure before disconnecting hydraulic 4.
Page 494 FIGURE 8-3. TIE ROD INSTALLATION 5. A torque wrench should be used to tighten the nuts in the pattern as shown in Figure 8-4. The tie rods should be tightened evenly to 160 ft. lbs. (217 N.m) torque in the following sequence.
Page 495 FIGURE 8-5. INLET SECTION DISASSEMBLY 1. Capscrew 6. Sleeve 11. Poppets 2. Inlet Cover 7. Low Pressure Relief 12. Springs 3. Spring (Orange) 8. O-Rings 13. Cover 4. Main Relief Valve 9. Inlet Valve Body 14. Capscrews 5. Spring 10. O-Rings NOTE: If restrictor poppet removal in cover (1) is required, refer to step 4 and Figure 8-6.
Page 496 Assembly 4. Remove restrictor poppet (1, Figure 8-8). Remove and discard O-ring (2) and backup ring 1. Coat all parts including housing bores with clean (3), if used. Note the position of the restrictor type C-4 hydraulic oil. Lubricate O-rings lightly when removed to insure correct reassembly.
Page 497 FIGURE 8-10. SPOOL SECTION ASSEMBLY 1. Cover 8. Spring (Blue) 15. Spool Housing 22. Spool End 2. Spring Seat 9. Spool End 16. Cover 23. Spool 3. Spring 10. Poppet (White) 17. Plug 24. Spool End 4. Plug 11. Spring Seat 18.
Page 498 6. Remove plug (4, Figure 8-10) from end of spool Assembly (7). Remove spring seat (2) and spring (3). 1. Lubricate O-rings (18 & 19, Figure 8-10), with Remove poppet (5) and spool end (6). clean hydraulic oil. Install O-rings in spool housing and install cover (16).
Page 499: Hoist Pilot Valve
HOIST PILOT VALVE 2. Position hydraulic lines (2, 13, 14 and 15) over valve ports and assemble fittings. Tighten Removal hydraulic line connections securely. 3. Place hoist control lever in spring-centered 1. Place the hoist control lever in the body down position.
Page 500 3. Remove snap ring (1, figure 8-12), capscrews (6), cap (24), spacer (23), and detent sleeve (22). Detent Balls (2) and (21) will fall free when the cap and detent sleeve are removed. Sepa- rate cap (24), spacer (23) and detent sleeve (22), as this will be necessary for reassembly.
Page 501 Cleaning and Inspection 5. Install tie rods. Install tie rod nuts. Tighten tie rod nuts to the torques shown in Figure 8-15. 1. Clean all parts including housings in solvent and 6. Install a new O-ring (27, Figure 8-12) and wiper blow dry with compressed air.
Page 502: Pilot Operated Check Valve
BODY UP LIMIT SOLENOID The body up limit solenoid valve (11, Figure 8-11) is located inside the hydraulic cabinet behind the oper- ators cab. This valve has no serviceable parts except The hoist cylinder weighs approximately 2200 for O-ring replacement. Should the solenoid valve lbs.
Page 503 7. At the lower mount, straighten drive lock plate 7. Raise and lower body several times to bleed air tabs to allow capscrew removal. Remove all from cylinder. Check for proper operation and capscrews (1, Figure 8-17), locking plate (2) inspect for leaks.
Page 504 FIGURE 8-18. HOIST CYLINDER L8-12 Hoist Circuit Component Repair L08031...
Page 505 Disassembly NOTE: A retainer bar is required to prevent the first and second stage cylinders from dropping out when 1. If removal of the hoist cylinder eye bearings is the housing is inverted. necessary, remove retainer ring (4, Figure 8- 17) and press out bearing (5).
Page 506 Cleaning and Inspection NOTE: Use only fresh cleaning solvent, lint free wiping cloth and dry filtered compressed air when cleaning and handling hydraulic cylinder parts. Immediately after cleaning and inspection, coat all surfaces and parts with clean hydraulic oil (Type C- 1.
Page 507 ASSEMBLY OF QUILL AND CYLINDER NOTE: Use only new seals, bearings and O-rings during reassembly. Thoroughly lubricate all parts and seals with hydraulic oil to aid in assembly and to provide lubrication during initial operation. Quill Installation 1. The plugs (3, Figure 8-20) and the check balls (4) in the quill should be checked during any cylinder repair to insure the plugs are tight and ball seats are not damaged.
Page 508 Installation of Check Balls and Plugs in Quill 1. Use the newer plugs and make certain threads in quill tube and on plugs are clean and dry The check balls (4, Figure 8-20) in the side of the (free of oil and solvent). quill assembly (2) are held in place with threaded 2.
Page 509 Assembly of Cylinder 1. Install seals (15, Figure 8-18) and bearing (14) on second stage cylinder. Install bearings (19) and buffer seal (18), rod seal (20) and rod wiper (21) on first stage cylinder. Lubricate with clean hydraulic oil (Type C-4). 2.
Page 510 COUNTERBALANCE MANIFOLD The counterbalance manifold is located to the rear of the hoist valve. The internal counterbalance valve relieves excessive pressure that can develop in the annulus area of the hoist cylinders if the load sticks to the tail of the body as the body goes overcenter while dumping.
Page 511: Disabled Truck Dumping Procedure
(4) to the power up circuit of 5. Repeat step 4 to dump the disabled truck. the disabled truck. NOTE: If both trucks are a Model 830E, the hoses Lowering the Body: will be installed at the quick disconnects shown in 6.
Page 512 NOTES: L8-20 Hoist Circuit Component Repair L08031...
Page 513: Hydraulic Checkout Procedure
HYDRAULIC CHECKOUT PROCEDURE STEERING AND BRAKE PUMP To Bleed Air From Pump: a. With the engine “Off” and the hydraulic oil Pressure Check And Adjustment level in the tank is at the proper level, open Procedure shut-off valve in steering pump suction line. NOTE: If steering and brake pump has just been b.
Page 514: Bleeddown Manifold
NOTE: Allow adequate time for the accumulator to Leakage Check fully charge after start up. To check for worn piston pump, measurement of the 5. Start engine and run at low idle. The steering leakage can be made from the case drain while the pump with unloader valve is preset to unload pump is under pressure.
Page 515: Shock & Suction Valves
SHOCK & SUCTION VALVES Shock & Suction Valve Settings Relieve pressure before disconnecting hydraulic lines. Tighten all connections securely before applying pressure. Hydraulic fluid escaping under pressure can have sufficient force to enter a person's body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a FIGURE 10-3.
Page 516: Leakage Tests
LEAKAGE TESTS Bleeddown Manifold 3. Disconnect hoist pilot valve return line (15, Fig- ure 10-4). Plug the port on bleeddown manifold. Relieve pressure before disconnecting hydraulic lines. Tighten all connections securely before applying pressure. Hydraulic fluid escaping Hydraulic tank oil level is above the level of this under pressure can have sufficient force to enter return line.
Page 517 1. Bleeddown Solenoid 2. Quick Disconnect, Brake System 3. To Steering Accumulators 4. Low Steering Pressure Switch 5. Relief Valve (500 psi) 6. Flow Amplifier 7. Feedback Pressure to Unloader Valve 8. Check Valve 9. Relief Valve (4000 psi) 10. Bleeddown Manifold Valve Assembly 11.
Page 518: Troubleshooting Chart
TROUBLESHOOTING CHART (Steering Circuit) Trouble Possible Cause Suggested Corrective Action Overloaded steering axle. Reduce axle loading. Slow steering, hard Malfunctioning relief valve. System Replace relief valve. pressure lower than specified. steering or loss of power assist Worn or malfunctioning pump. Replace pump.
Page 519 TROUBLESHOOTING CHART (Steering Circuit) Trouble Possible Cause Suggested Corrective Action Broken or worn linkage between Check for loose fitting bearings at anchor cylinder and steered wheels. points in steering linkage between cylinder Excessive free play at and steered wheels. steered wheels Leaky cylinder seals.
Page 520: Steering Pump
TROUBLESHOOTING CHART (Steering Pump) Trouble Possible Cause Suggested Corrective Action Trapped air inside steering pump. Bleed trapped air. Refer to “Pressure Check And Adjustment Procedure”, this Section. Broken pump drive shaft. Replace pump drive shaft. No pump output Excessive circuit leakage. Check for loose fittings, broken or cracked tubes.
Page 521 TROUBLESHOOTING CHART (Steering Pump) Trouble Possible Cause Suggested Corrective Action Low compensator pressure setting. Check compensator pressure setting. Fluid too cold or viscosity too high. Use proper viscosity oil or warm oil before starting. Air leak at inlet connection. Inspect inlet hose and connections for looseness.
Page 522 TROUBLESHOOTING CHART (Flow Amplifier - Refer to Figure 10-5) Trouble Possible Cause Suggested Corrective Action Stuck piston (position 2, Figure 10- Disassemble and check piston movement. Slow or hard steer Heavy steering wheel Dirty throttle-check valve, (position Disassemble and clean the throttle check movement with a simul- 3) or dirty orifice screw (position 4).
Page 523 FIGURE 10-5. FLOW AMPLIFIER VALVE L10016 05/03 Hydraulic Check-out Procedure L10-11...
Page 524 CHECKING HOIST SYSTEM PRESSURES NOTE: If relief valve or hoist valve assembly has NOTE: Each hoist pump section supplies oil to a been replaced or rebuilt, hoist relief valve pressure separate inlet section on the hoist valve. Each inlet should be checked. section on the hoist valve contains a power up relief valve.
Page 525 Power Down Relief Pressure Adjustment 1. Install a 0-3500 psi (0-25,000 kPa) pressure gauge at the power down test port “TPD” (3, Figure 10-9) on the counterbalance manifold (2). 2. With engine at low idle, allow the steering accu- mulator to fill and the pump to unload. With the body resting on the frame, place the hoist lever in the POWER DOWN position and then read pressure at “TPD”...
Page 526 Hoist Counterbalance Valve Adjustment Counterbalance Valve Pressure Check Only: 1. Start the engine. At low idle, raise the body and Preparation: as it extends to the third stage, read the pres- Note: The ports and valves referred to in the sure on the gauge connected to the “TR”...
Page 527: Counterbalance Valve
1.) If pressure is still below 3000 psi (20.7 Counterbalance Valve Adjustment MPa), continue increasing engine speed 1. Loosen locknut on adjustment stem of counter- in steps of 300 rpm, while in third stage balance valve (4, Figure 10-9) on manifold. and observing pressure gauge.
Page 528 TROUBLESHOOTING CHART (Hoist Pump) Trouble Possible Cause Suggested Corrective Action Visible damage in the following areas: Change hydraulic oil. • Sandblasted band around pressure plate Hydraulic filters may need changing. bores • Angle groove on Verify correct filter elements are being used. face of pressure plate Abrasive wear caused by fine parti- •...
Page 529 TROUBLESHOOTING CHART (Hoist Pump) Trouble Possible Cause Suggested Corrective Action • Housing scored heavily Thoroughly clean and flush hydraulic sys- Damage caused by metal object - tem. • Inlet peened and Object not removed during a previous battered Check other system components for possi- failure repair.
Page 530: Hydraulic System Flushing Procedure
HYDRAULIC SYSTEM FLUSHING PROCEDURE The following instructions outline the procedure for 12. Increase engine speed to full throttle and steer flushing the hydraulic system: full left and full right. 1. Shut down engine and turn key switch “Off”. NOTE: Hydraulic tank oil temperature should be Allow at least 90 seconds for the accumulator 110°...
Page 531 SECTION M OPTIONS AND SPECIAL TOOLS INDEX ANSULFIRE CONTROL SYSTEM MANUAL (M02004) ....M2-1 Operation ......... M2-1 Inspection and Maintenance .
Page 532 NOTES: M1-2 Index M01047...
Page 533: Operation
FIRE CONTROL SYSTEM (MANUAL) The fire control system aids in protecting the machine fluidized chemical to flow to the nozzles. The nozzles in the event of a fire. The system consists of: will direct the agent at the fire and extinguish the flames. •...
Page 534: Recharging Procedures
3. Remove each extinguisher from its bracket. 4. Disassemble bursting disc union and replace the ruptured bursting disc with flat side toward ex- tinguisher. 5. Fill tank with dry chemical to not more than three inches (76 mm) from the bottom of the fill opening. 6.
Page 535: Alternator And Wheelmotor Cooling Air Filter System (M04002)
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM The cooling air for the alternator and wheelmotors passes through a filter assembly prior to entering the blower on rear of alternator. The filter housing is mounted on the inlet of the air duct. The dirt removed by the filter is drawn off each end of the filter housing by a hydraulic motor driven blower and discharged to atmosphere.
Page 536 91456 FIGURE 4-1. BLOWER AIR FILTERING SYSTEM 1. Air Filter Assembly 4. Relief Valve 7. Evacuation Blower 2. Mounting Hardware 5. Hydraulic Motor 8. Electrical Control Cabinet 3. Scavenge Tubing Elbow 6. Blower Discharge M4-2 Alternator and Wheelmotor Cooling Air Filter System M04002 12/89...
Page 537 90191 FIGURE 4-2. HYDRAULIC PUMP 1. Rear Cover 7. Drive Gear 12. Shaft Seal 2. Seal 8. Center Section 13. Snap Ring 3. Seal Retainer 9. Front Wear Plate 14. Stud 4. Rear Wear Plate 10. Front Cover 15. Lockwasher 5.
Page 538: Blower Drive Motor
91455 FIGURE 4-3. BLOWER AND HYDRAULIC MOTOR ASSEMBLY 1. Fan Assembly 4. Hydraulic Motor 6. Locking Collar 2. Blower Shaft 5. Motor Mounting 7. Bearings 3. Flex Coupling Capscrews 6. Install front cover, tighten nuts to 115 ft.lbs. (156 4. Connect hoses, O-rings and split flange clamps. N-m) torque.
Page 539 91457 FIGURE 4-4. HYDRAULIC MOTOR 1. Gear and Shaft 5. Mounting Flange 9. Gear Plate 13. Capscrew 2. Key 6. Idler Gear 10. O-ring 14. Washer 3. Shaft Seal 7. Bushing 11. O-ring 15. Cover Plate 4. Snap Ring 8. O-ring 12.
Page 540 a. To remove the dowels, use a rod or punch and Assembly hammer to drive them out. Place driver inside 1. Using an arbor press, press the new seal (3, Figure of dowel and against end of dowel on opposite 4-4) into flange bore.
Page 541: Blower Bearing Repair
14. With O-ring in flange plate facing down and keep- ing plate true with shafts, slide it down until it contacts dowels in gear plate. Bump flange very lightly with hands or plastic hammer to force the plate down on dowels, at the same time making sure grease is holding O-rings in grooves.
Page 542: Air Cleaner
4. Remove bearing from shaft. AIR CLEANER 5. Clean all parts and inspect shaft and housing. Assembly Remove any scores or burrs from shaft. If either shaft or housing are damaged beyond use, the The air cleaner separates dirt from air entering the complete bearing housing assembly must be re- cooling blower at the rear of the main alternator.
Page 543: Wiggins Quick Fill Fuel System (M05002)
WIGGINS QUICK FILL FUEL SYSTEM FUEL RECEIVER Keep the cap on the receiver to prevent dirt build up in The fuel receiver (3, Figure 5-1) is normally mounted valve area and nozzle grooves. If fuel spills from tank on the fuel tank (1). Optional locations are the left hand breather valve, or tank does not completely fill, check frame rail (Figure 5-3) or at the Service Center in front.
Page 544: Tank Breather Valve
TANK BREATHER VALVE Removal Unscrew breather valve (2, Figure 5-1) from tank (1). Installation Screw breather valve into tank. Disassembly 1. Remove spring clamp (4, Figure 5-2) from outlet. 2. Pull off rubber cover and screen (3). 3. Unscrew nut (5) from top of breather valve. Re- move cover (6), spring (7), and steel ball (8).
Page 545 LEFT SIDE FILL Keep the cap on the receiver to prevent dirt build up in This location permits fueling the truck from the left side. valve area and nozzle grooves. If fuel spills from tank breather valve, or tank does not completely fill, check breather valve to see that float balls are in place and outlet screen is clean.
Page 546 NOTES M5-4 Wiggins Quick Fill Fuel System M05002 10/96...
Page 547: Buckeye Quick Fill Fuel System (M05003)
BUCKEYE QUICK FUEL SYSTEM FUEL TANK BREATHER VALVE Maintenance Normal maintenance involves cleaning or replacement of the breather valve filter during 1000 hour servicing. Operation in extremely dusty conditions may require more frequent cleaning or replacement intervals. Filter Service 1. Remove three capscrews (7, Figure 5-1) on vent housing.
Page 548: Fuel Receiver
FUEL RECEIVER The fuel receiver (3, Figure 5-2) is mounted on the fuel tank (2). Keep the cap on the receiver to prevent dirt build-up during truck operation. If fuel spills from breather valve or tank does not fill completely, check breather to see that the balls are in place and the filter is clean.
Page 549: Engine Coolant Heater (M07001)
ENGINE COOLANT HEATER To aid in cold weather starting, the truck can be HEATING ELEMENT equipped with cooling system heaters. Two high ca- pacity coolant heating units are mounted under the Removal engine on the power module subframe. The system 1.
Page 550: Thermostat
b. Screw heating element into cartridge and tighten securely to insure against leaks. 2. Connect the electrical leads. 3. Slide element cover into position and secure with screws. 4. Open shut-off valves. 5. Plug in the external power source. After allowing time for the element to warm up, outlet hoses should feel warm to the touch.
Page 551: Special Tools
SPECIAL TOOLS PART NO. DESCRIPTION Suspension & EB1759 NItrogen Charging Accumulator Nitrogen Charging PART NO. DESCRIPTION Power Module TY2930 Roll-Out Assembly Removal & Installation PART NO. DESCRIPTION TG1106 Eye Bolt, .75–10 UNC Misc. lifting requirements WA4826 Eye Bolt, 1.25–7 UNC M08005 7/02 Special Tools M8-1...
Page 552 PART NO. DESCRIPTION TZ3535 Offset Box End Miscellaneous Wrench, 1 1/2" PART NO. DESCRIPTION TZ2734 3/4" Female Adapter Torque Wrench Extension PART NO. DESCRIPTION TZ2733 Tubular Handle Use with TZ3535 & TZ2734 M8-2 Special Tools M08005 7/02...
Page 553 PART NO. DESCRIPTION Installation of Front TY2150 Seal Installation Wheel Bearing Tool Face Seals PART NO. DESCRIPTION Rear Suspension TZ0992 Alignment Sleeve And Anti-sway Bar Installation TY4576 Alignment Sleeve Steering Linkage Assembly M08005 7/02 Special Tools M8-3...
Page 554 PART NO. DESCRIPTION Engine Turning To Rotate ED8860* Tool Engine Crankshaft (MTU Engine Only) NOTE: To use this tool for the MTU/DDC 4000 Series Engine, it must be used with the locally made Adapter Plate. * This tool may also be acquired as MTU Part Number F6 555 766.
Page 555 Puller Tool dimensions suspension piston shown below KC7091 Pusher Capscrews, 1.12 x 7 in. Use for 830E, AFE 32 ONLY WA0365 Hardened Flat Washers 1.12 in. KC7095 Pusher Capscrews, 1.25 x 8 in. Use for 830E, AFE 50 ONLY WA0366 Hardened Flat Washers 1.25 in.
Page 556 NOTES M8-6 Special Tools M08005 7/02...
Page 557: Environmental Impact
AIR CONDITIONING SYSTEM Environmental Impact Environmental studies have indicated a weakening of the earth’s protective Ozone (O ) layer in the outer strato- sphere. Chloro-flouro-carbon compounds (CFC’s), such as R-12 refrigerant (Freon), commonly used in mobile equipment air conditioning systems, have been identified as a possible contributing factor of the Ozone depletion. Consequently, legislative bodies in more than 130 countries have mandated that the production and distribution of R-12 refrigerant be discontinued after 1995.
Page 558: Principles Of Refrigeration
(HFC) refrigerant, commonly identified as HFC-134a or R-134a, is being used in most current mobile air condition- ing systems. Additionally, the practice of releasing either refrigerant to the atmosphere during the charging/ recharging procedure is prohibited. These restrictions require the use of equipment and procedures which are significantly different from those tradi- tionally used in air conditioning service techniques.
Page 559 REFRIGERATION - THE ACT OF COOLING THE REFRIGERATION CYCLE • There is no process for producing cold; there is In an air conditioning system, the refrigerant is circu- only heat removal. lated under pressure through the five major compo- nents in a closed circuit. At these points in the system, •...
Page 560: Air Conditioner System Components
AIR CONDITIONER SYSTEM COMPONENTS Condensing of the refrigerant is the change of state of the refrigerant from a vapor to a liquid. The action is COMPRESSOR (Refrigerant Pump) affected by the pressure of the refrigerant in the coil and air flow through the condenser. Condensing pres- The compressor is where the low pressure side of the sure in an AC system is the controlled pressure of the system changes to high pressure.
Page 561 EXPANSION BLOCK VALVE EVAPORATOR The expansion block valve controls the amount of The evaporator cools and dehumidifies the air before it refrigerant entering the evaporator coil. Both internally enters the cab. Cooling a large area requires that large and externally equalized valves are used. volumes of air be passed through the evaporator coil for heat exchange.
Page 562: Electrical Circuit
ELECTRICAL CIRCUIT COMPRESSOR CLUTCH The air conditioner' s electrical circuit is fed from an An electromagnetic clutch is used in conjunction with accessory circuit and is fused with a 30-ampere circuit the thermostat to disengage the compressor when it is breaker.
Page 563 TRINARY™ SWITCH • Fan Clutch - The mid-range function actuates the engine fan clutch, if installed. • High Pressure - This switch opens and disen- This switch is mounted on the receiver-drier and has gages the compressor clutch if system pressure three functions, as implied by the name: rises above the 300 - 350 psi range.
Page 564: System Servicing
SYSTEM SERVICING Servicing an air conditioning system really means closely monitoring refrigerant flow. For this reason, the following procedures deal extensively with the proper use, handling, care and safety factors involved in the Federal regulations prohibit venting R-12 and R-134a refrigerant quality and quantity in an air condi- R134a refrigerant into the atmosphere.
Page 565 At present time, General Motors part number (12345923) Condenser 2-3 ounces is the oil that is furnished in the system on Komatsu Evaporator 1 ounce trucks. This clear oil can be found at AC Delco dealers.
Page 566 REFRIGERANT Recycled Refrigerant Recycled refrigerant has been extracted from a mobile air conditioning system using a recovery unit. The refrigerant is cleaned by the recovery unit as it passes An unclear sight glass on R-134a systems can indi- through filters located on the unit that meet specifica- cate that the system may be low on refrigerant.
Page 567: Service Tools And Equipment
SERVICE TOOLS AND EQUIPMENT RECOVERY/RECYCLE STATION Whenever refrigerant must be removed from the sys- tem, a dual purpose station as shown in Figure 9-3, Mixing different types of refrigerant will damage performs both recovery and recycle procedures which equipment. Dedicate one recovery/recycle station follows the new guidelines for handling used refriger- to each type of refrigerant processing to avoid ant.
Page 568 FIGURE 9-5. R-134a SERVICE VALVE FIGURE 9-6. VACUUM PUMP 1. System Service Port 3. Service Hose Fitting Connection VACUUM PUMP 2. Quick Connect The vacuum pump (Figure 9-6) is used to completely evacuate all of the refrigerant, air, and moisture from the system by deliberately lowering the pressure within SERVICE VALVES the system to the point where water turns to a vapor...
Page 569: Manifold Gauge Set
MANIFOLD GAUGE SET A typical manifold gauge set (Figure 9-7) has two screw type hand valves to control access to the sys- tem, two gauges and three hoses. The gauges are used to read system pressure or vacuum. The manifold and hoses are for access to the inside of an air condi- tioner, to remove air and moisture, and to put in, or remove, refrigerant from the system.
Page 570 INSTALLING MANIFOLD GAUGE SET Before attempting to service the air conditioning sys- tem, a visual inspection of both the engine and system components is recommended. Particular attention should be given to the belts, hoses, tubing and all attaching hardware plus the radiator cap, fan clutch, and thermostat.
Page 571 Purging Air From Service Hoses The purpose of this procedure is to remove all the The initial purging is best accomplished when con- air trapped in the hoses prior to actual system test- nected to recovery or recycle equipment. With the ing.
Page 572: System Performance Test
SYSTEM PERFORMANCE TEST Stabilizing the AC System This test is performed to establish the condition of all components in the system. Observe these conditions during testing: 1. Start engine and operate at 1200 to 1500 RPM. During this stabilization period, do not open hand 2.
Page 573: System Leak Testing
SYSTEM LEAK TESTING Refrigerant leaks are probably the most common Electronic leak detector cause of air conditioning problems, resulting from (Refer to Figure 9-4). As the test probe is moved into improper or no cooling, to major internal component an area where traces of refrigerant are present, a damage.
Page 574: System Repair
SYSTEM REPAIR Hoses and Fittings When replacing hoses, be sure to use the same type The following service and repair procedures are not and ID hose you removed. When hoses or fittings are any different than typical vehicle service work. How- shielded or clamped to prevent vibration damage, be ever, AC system components are made of soft metals sure these are in position or secured.
Page 575 Receiver-Drier Clutch The receiver-drier can not be serviced or repaired. It Clutch problems include electrical failure in the clutch must be replaced whenever the system is opened coil or lead wire, clutch pulley bearing failure, worn or for any service. The receiver-drier has a pressure warped clutch plate or loss of clutch plate spring tem- switch to control the clutch, and should be removed per.
Page 576 Before a compressor is dismissed as being seized, a Do not drive or pound on the clutch plate, hub check for proper voltage to the coil should be per- assembly, or shaft. Internal damage to the com- formed. In addition, the coil should be ohm checked for pressor may result.
Page 577 3. Remove locknut (4) using thin wall socket (1, Fig- 5. Remove square key (1, Figure 9-13) from the key- ure 9-11) or the equivalent. Use clutch hub hold- ways. ing tool (2), spanner wrench (J-9403), or the equivalent to hold clutch plate (3) while removing the locknut.
Page 578 PULLEY REMOVAL 10. Tighten the center screw on the puller against the shaft of the compressor to remove the pulley. 11. Clean the pulley and pulley bearing with solvent. Inspect the assembly for damage. Check the bearing for brinneling, excessive looseness, noise, and lubricant leakage.
Page 579 CLUTCH ASSEMBLY INSTALLATION 1. Insert square key (1, Figure 9-13) into the keyway 3. Thread drive plate installer (1, Figure 9-18) onto in the clutch hub. Allow the key to protrude about the shaft of the compressor. Spacer (2) should be 4.5 mm (0.18 in.) from the outer edge of the hub.
Page 580 RECOVERING AND RECYCLING THE 9. Check the system pressure after the recovery REFRIGERANT equipment stops. After five minutes, system pres- sure should not rise above “0” gauge pressure. If Draining the Oil from the Previous Recovery Cycle the pressure continues to rise, restart and begin the recovery sequence again.
Page 581: Evacuating The System
Evacuating the System Evacuating the complete air conditioning system is required in all new system installations, and when repairs are made on systems requiring a component replacement (system opened), or a major loss of refrig- erant has occurred. All these conditions will require that a vacuum be pulled using a vacuum pump that com- pletely removes any moisture from the system.
Page 582 Charging the AC System When charging the system, it is possible to put it in as a The moisture must turn to gas before the pump can pull gas or as a liquid. Adding refrigerant as a liquid is it out. The moisture takes time to boil away, so that it faster but can damage the compressor if not done cor- can be drawn out of the system.
Page 583: Troubleshooting
TROUBLESHOOTING PRE-DIAGNOSIS CHECKS • Fan and Shroud - Check for proper operation of fan clutch. Check installation of fan and shroud. If the system indicates Insufficient cooling, or no cool- • Heater/Water Valve - Check for malfunction or ing, the following points should be checked before pro- leaking.
Page 584 DIAGNOSIS OF GAUGE READINGS & SYSTEM 4. Compare evaporator discharge air temperature PERFORMANCE reading to see if it matches the recommended temperature for the ambient temperature and The following Troubleshooting Chart lists typical mal- gauge readings obtained. functions encountered in air conditioning systems. Indi- cations and or problems may differ from one system to 5.
Page 585 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS PROBLEM: Insufficient Cooling Indications: Low side pressure - LOW. High side pressure - LOW. Discharge air is only slightly cool. Possible Causes Suggested Corrective Actions - Low refrigerant charge, causing pressures to be Check for leaks by performing leak test. slightly lower than normal.
Page 586 PROBLEM: Extremely Low Refrigerant Charge in the System Indications: Low side pressure - LOW. High side pressure - LOW. Discharge air is warm. The low pressure switch may have shut off the compressor clutch. Possible Causes Suggested Corrective Actions - Extremely low or no refrigerant in the system. Check for leaks by performing leak test.
Page 587 PROBLEM: Air and/or Moisture in the System Indications: Low side pressure - HIGH High side pressure - HIGH Discharge air is only slightly cool. Possible Causes Suggested Corrective Actions - Leaks in system. Test for leaks, especially around the compressor shaft seal area.
Page 588 PROBLEM: Expansion Valve Stuck Open Indications: Low side pressure - HIGH High side pressure - Normal Air from vents in the cab seems warm or only slightly cool. Possible Causes Suggested Corrective Actions The expansion valve is stuck open and/or the Test: Operate the AC system on it' s coldest capillary tube (bulb) is not making proper contact setting for a few minutes.
Page 589 PROBLEM: Compressor Malfunction Indications: Low side pressure - HIGH High side pressure - LOW Compressor operates noisily. Possible Causes Suggested Corrective Actions Repair Procedure: If the belt is worn or loose, - Defective reed valves or other internal components. replace or tighten it and recheck system perform- ance and gauge readings.
Page 590 PROBLEM: Condenser Malfunction or System Overcharge Indications: Low Side High High Side High Discharge air may be warm. High pressure hoses and lines are very hot. Possible Causes Suggested Corrective Actions - Lack of air flow through the condenser fins Repair Procedure: Check the engine cooling system components, fan and drive belt, fan clutch operation, and the radiator shutter.
Page 591: Preventive Maintenance Schedule For Ac System
Preventive Maintenance Schedule for AC System Truck Serial Number___________________________ Last Maintenance Check:_______________________ Site Unit Number______________________________ Name of Service Technician________________ Date:____________Hour Meter:_________________ NOTE: Compressor should be run at least 5 minutes (40°F minimum ambient temperature) every month, in Maintenance Interval order to circulate oil and lubricate components. COMPONENT (months) Maintenance Interval...
Page 592 NOTES: M9-36 Air Conditioning System 05/02 M09010 for HFC 134a Refrigerant...
Page 593: Radiator Shutters
RADIATOR SHUTTERS Operation The optional radiator shutters aid in maintaining proper engine coolant temperature, primarily in cold climate Hydraulic Circuit operations. Hydraulic oil pressure to operate the shutter assembly actuator cylinder is supplied from the truck steering cir- The shutter system contains the following components: cuit.
Page 594 Komatsu SSDA16V1610 Engine: If equipped with the Komatsu engine, the ECM will pro- vide a +24VDC signal (circuit 65S) to energize relay K5 located on relay board #6. This will close the N.O. relay contacts fed by relay K3 which provides +24VDC when the key switch is ON.
Page 595 1. Shutter Solenoid Valve 2. Shutter Enable/Disable Switch 3. Relay K5 4. Relay Board #6 5. Relay K3 6. Electrical Cabinet 7. Junction Box (Rear of Cabinet) FIGURE 19-3. ELECTRICAL HOOKUP AND SCHEMATIC M19002 Radiator Shutters M19-3...
Page 596 NOTES M19-4 Radiator Shutters M19002...
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Page 655 Reserve Engine Oil System The Reserve Engine Oil System is designed to add more oil capacity to the engine sump and to reduce fre- quent servicing of the engine oil. The constant circula- tion of oil between the engine sump and reserve tank (9, Figure 31-1) increases the total volume of working oil.
Page 656 Operation LED Monitor Light • Steady - Pump 1 is withdrawing oil from the Engine oil is circulated between the engine oil pan (1, engine sump and bringing down the oil level. Figure 31-2) and the reserve tank (2) by two electrically driven pumps (Pump 1 and Pump 2) within a single •...
Page 657 Tank Fill Control (Optional) With the reserve oil system the engine oil level is held constant, with only the reserve tank needing routine fill- ing. The fill system automatically controls the filling of remote tank from a convenient ground level position. Filling of the tank to the proper “FULL”...
Page 658 Service Changing Oil 1. Drain both the engine sump and the reserve tank. Between oil drains, the only normal servicing required Refill both engine and reserve tank with new oil to is routine replenishment of oil at the reserve supply proper levels.
Page 659 Troubleshooting NOTE: There is a condition that would show a level higher than the controlled point. If both the engine and It is important to understand the LED signal for the reserve tank are overfilled, there is no room in the tank pumping unit.
Page 660 System Electrical Schematics FIGURE 31-4. SYSTEM SCHEMATIC 1. Pumping Unit (Pump 1 & Pump 2) 4. 15 Amp Circuit Breaker 2. Engine Oil Pressure Switch 5. Power Supply 3. Engine Subframe 6. Auxillary Box FIGURE 31-5. FILL SYSTEM SCHEMATIC 1. Fill Valve 4.
Page 661 SECTION N OPERATOR’S CAB INDEX TRUCK CAB ..............N2-1 Description .
Page 662 INSTRUMENT PANEL AND INDICATOR LIGHTS ........N5-10 Control Symbols.
Page 663: Truck Cab
ROPS structure will void certification. If various wiring harnesses. Hydraulic components modification or repairs are required, contact the are located outside of the interior and are accessed servicing Komatsu Distributor. through covers (2, Figure 2-1) on the front of the cab. FIGURE 2-1. CAB ASSEMBLY 1.
Page 664: Removal
Prior to cab removal or repair procedures, it may be necessary to remove the body to provide clearance for lifting equipment to be used. If body removal is not required, the body should be raised and the safety cables installed at the rear of the truck. Federal regulations prohibit venting air condi- tioning system refrigerants into the atmosphere.
Page 665: Installation
FIGURE 2-2. CAB HYDRAULIC AND ELECTRICAL CONNECTIONS 1. Cab 4. Hoist Valve Hoses 2. Steering Control Valve 5. Electrical Harness Connectors 3. Hydraulic Components Cabinet securely. Install clamps if removed during cab Installation removal. 1. Lift cab assembly and align mounting pad holes 4.
Page 666: Cab Door
CAB DOOR Door Adjustment If adjustment is necessary to insure tight closure of The cab door assemblies are similar except for the door, loosen striker bolt in the door jamb, adjust, and hinge side. Each is hinged on the rear edge with a retighten.
Page 667 3. Hold a piece of paper such as a dollar bill between where the door seal (4) will hit the skin of the cab and firmly close the door ensuring that it latches on the second catch. (The door latch mechanism has a double catch mecha- nism.) 4.
Page 668: Door Handle Plunger Adjustment
Door Handle Plunger Adjustment • Carefully lower the door panel a few inches. Hold If the door handle becomes inoperative, it can either glass at top to prevent it from dropping. Slide the be adjusted or replaced. The following is a procedure door panel toward the cab to disengage the for adjusting the exterior door handle plunger.
Page 669: Replace Door Glass
5. Before removing all door panel mounting Replace Door Glass screws, support the panel to prevent the 1. Remove hair pin clip (1, Figure 2-6) and bolt (2) assembly from dropping. Remove 15 mounting from the door check strap closes to the door. screws (5).
Page 670 7. Remove 2 screws (Figure 2-8) holding the roller track to the bottom of the door glass. FIGURE 2-10. FIGURE 2-8. 1. Screws 2. Rubber Felt Insert Remove the screw at the lower end of the window channels. It is necessary to pull the rubber felt insert 8.
Page 671 Lift door glass up in the frame (1, Figure 2-12) so that it is near the top. Holding the glass in place, tilt frame out at the top. Lift frame and glass straight up and out of door. Bracket (2, Figure 2-9) at bottom of glass must clear the door frame, if still on glass.
Page 672 FIGURE 2-14. FIGURE 2-15. 1. Capscrew & Nut 3. Mounting Screw - 2. Mounting Screws - Outside Door Handle 21. Lift door panel, regulator and glass up to align Latch 4. Latch Assembly screw holes in the panel with holes in door 5.
Page 673: Replace Door Window Regulator
Replace Door Window Regulator Replace Door Handle or Latch Assembly 1. Follow steps 1-6 procedure for door glass The cab doors are equipped with serviceable latch replacement. handle assemblies (inner and outer). If they become inoperative, they should be replaced by a new 2.
Page 674 Door and Door Hinge Seal Replacement 1. The door assembly seal has only three mem- bers to it (sides and top) and is glued on the door. This seal can be replaced by peeling the seal away from the door frame. Then use a suitable cleaner to remove the remaining seal and glue material.
Page 675: Glass Replacement
GLASS REPLACEMENT Replacement Procedure ADHESIVE-BONDED WINDOWS Recommended Tools/Supplies The first concern with all glass replacement is SAFETY! Wear heavy protective gloves and • Cold knife, pneumatic knife, or a piano wire cutting device, long knife. Cutout tools are safety eyeglass goggles when working with available at an auto glass supply store.
Page 676 8. Apply a continuous even bead of the adhesive WINDSHIELD & REAR GLASS approximately 0.38 in. (10 mm) in diameter to Two people are required to remove and install the the cab skin at a distance 0.50 - 0.63 in. (13 - 16 windshield or rear glass.
Page 677 Installation 3. After the glass is in place, go around the weath- erstrip and push in on the locking lip (2, Figure 1. If the weatherstrip material previously removed 2-18 or 2-19) to secure the glass in the weather- is broken, weathered, or damaged in any way, strip.
Page 678 NOTES: N2-16 Truck Cab 04/03 N02014...
Page 679: Cab Components
CAB COMPONENTS WINDSHIELD WIPERS Installation 1. Place wiper motor (1, Figure 3-1) into position The windshield wipers are operated by a 24 volt elec- on plate (2). tric motor. The wipers can be adjusted for a variable intermittent delay or a constant low or high speed by 2.
Page 680 Installation 4. If equipped, remove four capscrews (2, Figure 3-4) with washers. 1. Place wiper arm (1, Figure 3-2) into the position 5. Remove the pillow blocks (3) from the wiper noted during removal. Install washer (3) and compartment. nut (2). Tighten the nut to 142-177 in. lbs. (16- 20 Nm) torque.
Page 681: Windshield Washer
WINDSHIELD WASHER Operation The windshield washer, mounted on the right side of the hydraulic components cabinet behind the cab, has a 3.8 liter (1 gal) plastic reservoir (1, Figure 3-5) with a 24 volt electric pump (2). The washer is controlled by the windshield wiper switch mounted on the instrument panel and is acti- vated by pressing the knob.
Page 682 NOTES: N3-4 Cab Components N03018...
Page 683: Operator Comfort
OPERATOR COMFORT OPERATOR SEAT Seat Installation 1. Mount seat assembly to seat riser. Install cap- The operator's seat provides a fully adjustable cush- screws (10, Figure 4-1), lockwashers, flatwash- ioned ride for the driver's comfort and ease of opera- ers and nuts. Tighten capscrews to standard tion.
Page 684 HEATER/AIR CONDITIONER CONTROLS The heater assembly incorporates all the controls necessary for regulating the cab interior temperature; heated air during cold weather operation, outside air during mild temperatures and cooled, de-humidified air during warm weather operation. The following information primarily describes the heater system.
Page 685: Heater Components
HEATER/AIR CONDITIONER HEATER COMPONENTS The heater assembly incorporates all the controls nec- Figures 4-3 and 4-4 illustrate both the heater system essary for regulating the cab interior temperature; and air conditioning system parts contained in the cab heated air during cold weather operation and cooled, mounted enclosure.
Page 686: Filter
HEATER CORE Test The heater core (46, Figure 4-4) receives engine Visually inspect the flappers (11, or 43) and linkage coolant through the heater valve (14) when HEAT is for the function being diagnosed. Make certain the selected. If the temperature control potentiometer flapper is not binding or obstructed, preventing (37) is placed in between the red and blue area, or movement from one mode to the other.
Page 687 FIGURE 4-4. HEATER/AIR CONDITIONER ASSEMBLY 1. Blower Housing 13. Foam 26. Louver 39. Thermostat 2. Blower Wheel 14. Heater Valve 27. Louver Adapter 40. Hose 3. Cover Plate 15. Grommet 28. Foam 41. Switch, Blower 4. Venturi 16. Casing 29. Plate, Coil 42.
Page 688 NOTES: N4-6 Operator Comfort N04023...
Page 689: Operator Controls And Equipment
OPERATOR CONTROLS AND EQUIPMENT FIGURE 5-1. CAB INTERIOR - OPERATOR CONTROLS 1. Steering Wheel 6. Heater / Air Conditioner Controls 11. Radio, AM/FM Stereo, Cassette 2. Service Brake Pedal 7. Instrument Panel 12. Warning Lights Dimmer Control 3. Retarder Pedal 8.
Page 690: Steering Wheel And Controls
STEERING WHEEL AND CONTROLS The steering wheel (1, Figure 5-2) will telescope “in” and “out” and adjust through a tilt angle to provide a comfortable wheel position for most operators. HORN BUTTON The horn (2, Figure 5-2) is actuated by pushing the button in the center of the steering wheel.
Page 691 Installation 1. Insert capscrew (10) with lockwashers (11) and flatwashers (5) through brackets (8 & 9) and then through steering column flange. Add sec- ond flatwasher (5) and nut (13) to each cap- screw to hold parts together. Tighten nuts securely.
Page 692: Pedal Controls
PEDAL CONTROLS THROTTLE PEDAL The Throttle Pedal (4, Figure 5-4) is a foot operated pedal which allows the operator to control engine RPM depending on the amount of pedal depression. SERVICE BRAKE PEDAL The Service Brake Pedal (2, Figure 5-4) is a foot operated pedal controlling a hydraulic valve, which modulates pressure to the service brakes.
Page 693: Overhead Controls, Gauges, Etc
The windshield wipers (15, Figure 5-1) are powered by an electric motor. Refer to “Instrument Panel and The sample chart above applies to a model 830E Indicator Lights”, for location and description of the equipped with GE787 wheel motors with 31.875:1 windshield wiper and washer controls.
Page 694: Center Console Controls
"N" position and is in "NEUTRAL". The handle must gauge(s) shows the follow- be in neutral to start the engine. ing maximum recom- mended restriction: Komatsu SDA16V160 or The operator can select FOR- SSDA16V160 Engine: WARD drive by moving the 25 inches of H O vacuum.
Page 695 HOIST CONTROL ASH TRAY The hoist control lever (3) is a three position hand The ash tray (4, Figure53-5) is used for extinguishing operated device located to the right of the operator and depositing smoking materials. DO NOT use for seat.
Page 696 OVERRIDE SWITCH “IN” The override switch Push the Retard Speed (9) is spring loaded Control Switch knob “IN” to to the OFF position. turn “OFF”. When pushed in and held, the switch may “OFF” be used for several functions. • The override switch may be used to move the truck forward when the selector switch is in FORWARD, the dump body is raised, and the brakes are released.
Page 697 When the throttle pedal is released and the RSC KOMATSU ENGINE QUANTUM CONNECTOR switch is ON, dynamic retarding will activate at, or This connector (17, Figure 5-5) is for use by qualified above, the RSC dialed speed and will adjust truck personnel to access engine diagnostic information speed to maintain, the dialed speed.
Page 698 INSTRUMENT PANEL AND INDICATOR LIGHTS CONTROL SYMBOLS Many control functions are identified with “International” symbols that the operator should learn to recognize imme- diately. The operator must understand the function and operation of each instrument and control. This knowledge is essential for proper and safe operation of the machine. The following symbols are general indicators and may appear in multiple locations and combinations on the instru- ment panel.
Page 699: Instrument Panel
INSTRUMENT PANEL The operator must understand the function and oper- This knowledge is essential for proper and safe oper- ation of each instrument and control. Control func- ation of the machine. tions are identified with "International" symbols that Items that are marked OPTIONAL do not apply to the operator should learn to recognize immediately.
Page 700 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-7) Refer to Figure 5-7 for the following descriptions. The Engine Shutdown Timer DOES NOT turn off the (1, Figure 5-7) KEY SWITCH 24VDC electrical power. The keyswitch must be turned OFF The key switch is a three position (Off, Run, Start) to cause the engine to shut switch.
Page 701 (6, Figure 5-7) PANEL ILLUMINATION LIGHTS (12, Figure 5-7) WHEEL BRAKE LOCK CONTROL The instrument panel illumination lights are con- The Wheel Brake Lock should be used with the trolled by the panel light dimmer rheostat (29). engine running for dumping and loading operations only.
Page 702 27 to 28 volts with batteries in The tachometer registers engine crankshaft speed in fully charged condition. When hundreds of revolutions per minute (RPM). the key switch is ON and the Governed RPM (Komatsu Engine) engine is NOT running, the voltmeter indicates battery •...
Page 703 (21, Figure 5-7) WATER TEMPERATURE GAUGE (28, Figure 5-7) WINDSHIELD WIPER AND WASHER The water temperature gauge indicates the temperature of The windshield wiper control the coolant in the engine cool- switch is a four position rotary ing system. The temperature switch with intermittent wiper range after engine warm-up delay and wash feature.
Page 704 OVERHEAD STATUS / WARNING INDICATOR LIGHTS FIGURE 5-8. OVERHEAD STATUS / WARNING INDICATOR LIGHTS Row/ Indicator Indicator Color - Column Description Wire Index Row/ Indicator Indicator Color - Column Description Wire Index Retard Speed Control Yellow - 12MD/31R Hydraulic Oil Temp. Red - 12FD1/34TL Check Engine Yellow - 12MD7/419...
Page 705 INDICATOR LIGHTS Figure 5-8 illustrates the system indicator lights located on the Overhead Display, above the opera- tor's line-of-sight. The following describes the lamps shown in Figure 5-8 and should be referenced by the If the low steering warning light continues to illu- intersection of row locators A through E and column minate and the alarm continues to sound, low locators 1 through 6.
Page 706 D1. Electric System Fault B2. Low Automatic Lubrication Pressure The electric system fault warn- This amber light will illuminate ing light will flash on and off if the automatic lubrication sys- when a malfunction occurs in tem fails to reach 2,200 PSI (at electrical system.
Page 707 A3. Parking Brake E3. Stop Engine The AMBER parking brake The RED engine monitor warn- indicator will illuminate when ing light will illuminate if a seri- the parking brake is applied. engine malfunction Do not attempt to drive the detected electronic truck with the parking brake engine control system.
Page 708 B4. Manual Backup Lights A5. Not Used The AMBER indicator will illu- Not currently used. Reserved for future use or minate when manual options. backup switch is turned on. B5. High Wheel Motor Temperature (optional) When this light is illuminated and the alarm sounds, high wheel motor temperature is indicated.
Page 709 A5, D5, E5, A6, B6, C6, D6, (8) Lamp Test Switch E6: Blank The Lamp Test switch is pro- vided to allow the operator to (Reserved for future use) test the indicator lamps prior to starting the engine. Any lamp bulbs which do not illuminate should be replaced before operating the truck.
Page 710 NOTES: N5-22 Operator Controls N05056...
Page 711 SECTION P LUBRICATION AND SERVICE INDEX LUBRICATION AND SERVICE ............P2-1 LUBRICATION SPECIFICATIONS CHARTS .
Page 712 NOTES P1-2 Index P01028...
Page 713: Service Capacities
LUBRICATION AND SERVICE HYDRAULIC TANK SERVICE Recommended Preventive Maintenance will contrib- ute to the long life and dependability of the Komatsu There are two sight gauges on the side of the truck and its components. The use of proper lubri- hydraulic tank.
Page 714: Radiator Filling Procedure
COOLANT LEVEL CHECK Reserve Engine Oil System (Optional) Inspect the coolant sight gauge. If coolant cannot be The reserve oil tank for the engine is designed to add seen in the sight gauge, it is necessary to add cool- more oil capacity to the engine to reduce the frequent ant to the system before truck operation.
Page 715 P02039 Lubrication and Service P2-3...
Page 716: Hour (Daily) Lubrication And Maintenance Checks
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS Prior to each operating shift, a “walk around” inspec- tion should be performed. Check the truck for general condition. Look for evidence of hydraulic leaks; check all lights and mirrors for clean and unbroken lenses;...
Page 717 INITIALS cleaner vacuum gauges in operator cab. The air cleaner(s) should be serviced, if the gauge(s) shows the following maximum restriction: Komatsu SDA16V160 or SSDA16V160 Engine: 25 in. of H O vacuum. See Section “C” for servicing air cleaner elements. Empty air cleaner dust caps.
Page 718 50 HOUR LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10 hours/shift checks should Truck Serial Number _________________________ also be carried out at this time. Site Unit Number ____________________________ Date: ______________ Hour Meter: ____________ Name of Service Person ______________________ √ √ √ √ ’d COMMENTS INITIALS 1.
Page 719: Hour Lubrication And Maintenance Checks
100 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number_________________________ Site Unit Number ___________________________ Maintenance for every 10 & 50 hour Lubrication and Date:_______________ Hour Meter: ____________ Maintenance Checks should also be carried out at this time. Name of Service Person _____________________ √...
Page 720: Hour Lubrication And Maintenance Checks
250 HOUR LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10 & 50 hour Lubrication and Truck Serial Number _________________________ Maintenance Checks should also be carried out at Site Unit Number ____________________________ this time. Date: ______________ Hour Meter: ____________ NOTE: “Lube Key” references are to the Lubrication Name of Service Person ______________________ Specification Chart.
Page 721 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (CONTINUED) COMMENTS √ √ √ √ ’d INITIALS 6. COOLING SYSTEM - a. Check cooling system for proper coolant mixture. Add coolant mixture as required. b. COOLANT FILTERS - Change coolant fil- ters. Refer to engine manufacturer's Opera- tion and Maintenance Manual for coolant filter replacement instructions and recom- mended coolant mixture and additives.
Page 722 500 HOUR LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10 & 250 hour Lubrication and Truck Serial Number _________________________ Maintenance Checks should also be carried out at Site Unit Number ____________________________ this time. Date: ______________ Hour Meter: ____________ NOTE: “Lube Key” references are to the Lubrication ____________________ Name of Service Person Specification Chart.
Page 723: 1000 Hour Lubrication And Maintenance Checks
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10, 250 & 500 hour Lubrica- Truck Serial Number_________________________ tion and Maintenance Checks should also be carried Site Unit Number ___________________________ out at this time. Date:_______________ Hour Meter: ____________ Name of Service Person _____________________ NOTE: “Lube Key”...
Page 724 2500 HOUR MAINTENANCE CHECKS Maintenance for every 10, 250, & 500 hour Lubrica- Truck Serial Number _________________________ tion and Maintenance Checks should also be carried Site Unit Number ____________________________ out at this time. NOTE: "Lube Key" references are to Date: ______________ Hour Meter: ____________ the Lubrication Specification Chart.
Page 725: Hour Lubrication And Maintenance Checks
5000 HOURS LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10, 250, 500, 2,500 & 1,000 Truck Serial Number_________________________ hour Lubrication and Maintenance Checks should Site Unit Number ___________________________ also be carried out at this time. NOTE: "Lube Key" Date:_______________ Hour Meter: ____________ references are to the Lubrication Specification Chart.
Page 726 NOTES: P2-14 Lubrication and Service P02039...
Page 727: Automatic Lubrication System
AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION During the down stroke, the pump cylinder is extended into the grease. Through the combination The Lincoln Automatic Lubrication System is a pres- of shovel action and vacuum generated in the pump surized lubricant delivery system which delivers a cylinder chamber, the grease is forced into the pump controlled amount of lubricant to designated lube cylinder.
Page 728 FIGURE 3-2. AUTO LUBE SYSTEM INSTALLATION P3-2 Automatic Lubrication System P03022...
Page 729: System Components
SYSTEM COMPONENTS The flow control valve has been factory adjusted and the setting should not be disturbed. Filter (21, Figure 3-2) Solenoid Valve (5, Figure 3-1) A filter assembly mounted on the grease reservoir fil- The solenoid valve, when energized, allows oil to ters the grease prior to refilling the reservoir from the flow to the hydraulic motor.
Page 730: System Operation
System Operation the reservoir to the injectors (13), through a check valve (10) and to the vent valve (11) and Refer to Figure 3-3 & 3-4: the normally open pressure switch (9). 5. During this period, the injectors will meter the Normal Operation appropriate amount of grease to each lubrica- 1.
Page 731 Pressure Failure Detection Circuits 4. Once RB6-K6 is energized, it will latch and remain latched as long as the key switch is On. 1. When the lubrication cycle is initiated, 24VDC Also, RB6-K2 will remain energized and the flows through relay RB6-K4 (8, Figure 3-4) N.C. Low Lube Pressure Warning light will remain on contacts to a 1 minute delay timer (7).
Page 732: Injector Operation
INJECTOR OPERATION STAGE 1. The injector piston (2) is in its normal or "rest" posi- tion. The discharge chamber (3) is filled with lubri- cant from the previous cycle. Under the pressure of incoming lubricant (6), the slide valve (5) is about to open the passage (4) leading to the mea- suring chamber (1) above the injector piston (2).
Page 733: General Instructions
GENERAL INSTRUCTIONS LUBRICANT REQUIRED FOR SYSTEM Grease requirements will depend on ambient tem- peratures encountered during truck operation: • Above 90°F (32° C) NLGI No.2 multipurpose grease (MPG). • -25° to 90° F (-32° to 32° C) - Use NLGI No. 1 multipurpose grease (MPG).
Page 734 LUBRICANT PUMP Pump Housing Oil Level The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Oil level should be checked at 1000 hour intervals. To add oil, remove pipe plug (4, Figure 3-6) and fill housing to bottom of plug hole.
Page 735 INJECTORS (SL-1 Series "H") Injector Specifications • Each lube injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting to allow the use of external lubricating equipment. • Injector output is adjustable: Maximum output = 0.08 in³...
Page 736: System Checkout
SYSTEM CHECKOUT To check system operation (not including timer), pro- ceed as follows: 1. Turn keyswitch "ON" and start the engine. 2. Actuate the manual override (6, Figure 3-1) on the end of the solenoid valve. 3. The pump should operate and the system should build grease pressure.
Page 737: Pump Rebuild
PUMP REBUILD 13. Using a 0.50 in. (13 mm) diameter wooden or plastic rod, push the cup seal (22) and the pump cylinder (24) from the reciprocating tube. 14. Remove the pump plunger (20) from the plunger link rod (17). (A spanner wrench, which uses Be certain to bleed steering accumulators to the holes in the pump plunger, is required.) relieve hydraulic pressure and to relieve pump...
Page 738 FIGURE 3-9. LUBE PUMP ASSEMBLY 1. Screw 16. Cup Seal 31. Cover Gasket 45. Pipe Plug 2. Outer Weight 17. Plunger Rod 32. Gauge 46. Pump Housing 3. Inner Weight 18. Spring 33. Screw 47. Backup Ring 4. Retaining Ring 19.
Page 739 Assembly 8. Assemble crank rod assembly, to pump with Note: Use Loctite® 242 (or equivalent) thread locker bushings (13) and button head screws (12). on all torqued, threaded connections. Use extreme Tighten screws to 100 - 110 in. lbs. (11.3 - 12.4 care to prevent thread locker from flowing into adja- N.m) torque.
Page 740: System Troubleshooting Chart
SYSTEM TROUBLESHOOTING CHART If the following procedures do not correct the problem, contact a factory authorized service center. POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Pump Does Not Operate Lube system not grounded. Correct grounding connections to pump assembly and truck chassis. Electrical power loss.
Page 741 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Pressure Gauge Does Not Register Pressure No system pressure to the pump motor. Check hydraulic hose from steering system. No 24 VDC signal at pump solenoid. Determine problem in 24 VDC electric system. Pressure reducing valve set too low. Refer to "Pressure Control Valve Adjustment".
Page 742 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Timer Turns On At Intervals Two (2) To Ten (10) Times More Often Than Set Time Interval Electrical noise is being introduced into the power IMPORTANT: In some instances, electrical noise supply to the timer overcoming suppressor capacitor may be generated into vehicle electrical system causing uncontrolled turn-on of its output relay.
Page 743 Preventative Maintenance Procedures 4. Inspect all bearing points for a bead of lubricant around the bearing seal. The following maintenance procedures should be It is good practice to manually lube each bear- used to insure proper system operation. ing point at the grease fitting provided on each Daily Lubrication System Inspection Injector.
Page 744 NOTES: P3-18 Automatic Lubrication System P03022...
Page 745 ! " ! " " " % & ' ! " ! " & % & % & % & % & % & % & & % & % & % & % & % & % & % &...
Page 746 & % % & % % & % % & % % 9 - ' & % % & % % & % % & % % 9 +9 & % % & % % & % % & % % &...
Page 747 & % & % % 9 +9 9 -' 8 3 ' & % & % % 9 +9 9 -' 8 3 ' " ( . A4 + 0 +'+ & % & % % > ''+ " 9 -' "...
Page 748 " % % % % % % % % % + - ' % % % 0 - 0 & % " " $ B ' <' % % % % % % % % % " % % % ;...
Page 749: Alphabetical Index
SECTION Q ALPHABETICAL INDEX Accelerator Pedal, Electronic ....E2-62 Checkout Procedure ..... . J4-1 Troubleshooting .
Page 750 Hoist Pilot Valve ......L8-7 Hoist Cylinders ......L8-10 Decks .
Page 751 ® Rear HYDRAIR II Suspension....H3-1 Rear Tire and Rim ......G2-3 Nitrogen Specifications .
Page 752 Warnings and Cautions ....A4-1 Weights (Truck) ......A2-4 Tank Wheel Bearing Adjustment, Front Fuel .
Page 753 830E STATEX III ELECTRICAL SCHEMATIC (XS1400) ........
Page 754 NOTES R1-2 System Schematics R01060...
Page 756 HH354 Jun 03 Hydrauiic Schematic Brake System Electrical Schematic 830E Effective with A30650 & UP...
Page 757 NOTE: FIELD RETROFITS DO NOT HAVE CONNECTOR P268 HE481 June 03 Electrical Schematic Payload Meter III 730E: A30212 and UP 830E: A30650 and UP Sheet 1 of 1...

Komatsu 830E Shop Manual

Standard Charts and Tables

Section B Structures Index

Section C Engine Index

Section D Electrical System (24Vdc Non-Propulsion) Index

Section E Electrical Propulsion Components Index

Statex III Electrical System Checkout Procedure

1 SEQUENCE TESTS - (Engine Not Running)

2 Digital Input/Output Signals Tests - Fl275 Card Panel

3 Analog Input Signals Tests - Fl275 Card Panel

4 Speed Event Checks

5 Retard Speed Control System Check

6 Load Test Using Truck Retard Grids

7 Motor Field Current Check in Retarding

8 Miscellaneous Component Test and Adjustment

9 Optional Payload Meter (Plm II) Check-Out Procedure

10 Miscellaneous Charts

Section G Drive Axle, Spindle and Wheels Index

Section H ® Hydrair II Suspensions Index

Section J Brake Circuit Index

Section L Hydraulic System Index

Quick Links

Chapters

Troubleshooting

Related Manuals for Komatsu 830E

Summary of Contents for Komatsu 830E