Page 1 CEBM016202 Shop Manual DUMP TRUCK A30001 - A30035 SERIAL NUMBERS ®...
Page 2 NOTES:...
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 dis- closed except in accordance with written authorization from KAC.
Page 4 Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.
Page 5: A00040 8/06 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
TABLE OF CONTENTS SUBJECT ................SECTION GENERAL INFORMATION .
Page 8 KOMATSU MODEL 830E-AC TRUCK Introduction 8/06 A00040...
Page 9 SECTION A GENERAL INFORMATION INDEX MAJOR COMPONENTS & SPECIFICATIONS..........A2 GENERAL SAFETY AND OPERATION .
Page 10 NOTES A1-2 Index 02/94 A01001...
Page 11 MAJOR COMPONENT DESCRIPTION Truck And Engine Operator's Cab The 830E-AC Dump Truck is an off-highway, rear The operator cab has been engineered for operator dump truck with AC Electric Drive. The gross vehicle comfort and to allow for efficient and safe operation weight is 385 852 kg (850,650 lbs.).
Page 12 830E MAJOR COMPONENTS A2-2 Major Component Description 3/06 A02073...
Page 13 ... High Pressure Beta 12 Rating =200 grade and length, rolling resistance, and other parameters. *With Quick Disconnects for powering disabled truck Komatsu & G.E. must analyze each job condition to assure proper application. and system diagnostics.
Page 14 Non-heated body w/exhaust mufflers ..Standard Standard Komatsu body 27 669..(61,000) Standard tire weight . . . 21 081..(46,476) TIRES Radial Tires (standard) .
Page 15 WHEN REPAIRS ARE NECESSARY ..........A3-17 SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK ......A3-18 TRUCK OPERATION .
Page 16 DELAYED ENGINE SHUTDOWN PROCEDURE ........A3-32 EMERGENCY STEERING SYSTEM .
Page 17: General Safety
Before making any modification, consult your • Ensure all guards and covers are in their proper authorized regional Komatsu America Corp. position. Repair any damaged guards and distributor. Komatsu will not be responsible for covers. (See Walk-Around Inspection, later in injury damage caused this section.)
Page 18 Mounting And Dismounting Precautions For High Temperature Fluids • Never jump on or off the machine. Never climb • Immediately after machine on or off a machine while it is moving. operation, engine coolant, engine oil, and hydraulic oil are •...
Page 19 Optimum strength of the structure can only be achieved if it is repaired or modified as specified by Komatsu. A03030 3/06 General Safety and Operating Instructions...
Page 20: Precautions For Truck Operation
Check fuel, lubrication, and hydraulic systems for tors or technicians may attempt to operate or main- leaks. Repair any leaks. Clean any excess oil, tain a Komatsu machine. fuel or other flammable fluids, and dispose of properly. Safe practices start before the operator gets to the •...
Page 21: Warnings And Cautions
OPERATING THE MACHINE Mirrors, Windows, And Lights • Remove any dirt from the surface of the Starting The Engine windshield, cab windows, mirrors and lights. • NEVER ATTEMPT TO START THE MACHINE Good visibility may prevent an accident. BY SHORTING ACROSS THE STARTER •...
Page 22 • Check for flat tires periodically during a shift. If Traveling In The Truck the truck has been operating on a “flat”, the truck • When traveling on rough ground, travel at low must not be parked indoors until the tire cools. If speeds.
Page 23 Traveling On Slopes Avoid Damage To The Dump Body • Traveling on slopes could result in the machine • When working in tunnels, on bridges, under tipping over or slipping. electric cables, or when entering an enclosed area where there are height limits, always use •...
Page 24: Towing
TOWING When Loading The Truck Improper towing methods may lead to serious per- • Ensure the surrounding area is safe. If so, stop the machine in the correct loading position and sonal injury and/or damage. evenly load the body. • Tow with a solid tow bar.
Page 25: Working Near Batteries
WORKING NEAR BATTERIES Jump Starting With Booster Cables • Always wear safety glasses or goggles when Battery Hazard Prevention starting the machine with booster cables. • Battery electrolyte contains sulfuric acid and can • While jump starting with another machine, DO quickly burn the skin and eat holes in clothing.
Page 26: Precautions For Maintenance
• These tags are available from your Komatsu 2. Remove cable (3) from its stored position on the distributor. body, and install between rear body ear (1) and axle housing ear (4).
Page 27: During Maintenance
DURING MAINTENANCE Rules To Follow When Adding Fuel Or Oil • Spilled fuel and oil may cause slipping. Always Personnel clean up spills, immediately. • Only authorized personnel can service and repair • Always tighten the cap of the fuel and oil fillers the machine.
Page 28 Precautions With The Battery Maintenance Near High Temperatures And High Pressures • When repairing electrical system • Immediately after stopping the when performing truck, the engine coolant and welding, remove operating oils are at high negative (-) terminal of temperature and under high the battery to stop the pressure.
Page 29: Tires
When performing such maintenance, con- sharp stones on rough road surfaces. This may lead sult your authorized regional Komatsu distributor, or to serious injury or damage. the tire manufacturer.
Page 30: Additional Job Site Rules
ADDITIONAL JOB SITE RULES • Use this space to add any additional job site rules not covered in any of the previous discussions. • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ •...
Page 31: When Repairs Are Necessary
9. If a truck is to be towed for any reason, use a attempt repairs. rigid tow bar. Check the truck cab for decals for 2. Many components on the Komatsu truck are special towing precautions. (Also refer to the large and heavy. Ensure that lifting equipment -...
Page 32: Special Precautions For Working On A 830E-Ac Truck
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK Preliminary Procedures before Welding or Per- Engine Shutdown Procedure before Welding or forming Maintenance Performing Maintenance Prior to welding and/or repairing a 830E-AC dump Normal operation of the drive system at shutdown truck, maintenance personnel should attempt to should leave the system safe to maintain.
Page 33 DO NOT repair cable cleats by encircling the power cables with metal clamps or hardware. Always inspect power Notify your Komatsu service representative, cable insulation prior to servicing the cables and immediately. Only qualified personnel, specifi- prior to returning the truck to service. Discard cally trained for servicing the A-C drive system, cables with broken insulation.
Page 34 A3-20 General Safety and Operating Instructions 3/06 A03030...
Page 35: Truck Operation
Only qualified operators or technicians can hand holds or footholds, unless the engine has operate or maintain a Komatsu truck. been shut off and the system has been verified Safe practices start before the operator gets to the...
Page 36 A3-22 General Safety and Operating Instructions 3/06 A03030...
Page 37 8. Move behind the front wheel and inspect the 15. Open the rear hatch cover, turn on work light, if steering cylinder. Check for proper greasing necessary. Inspect for leaks around wheel and inspect the mounting hardware to ensure it motor mounting to rear housing, and also brake is all in place.
Page 38 23. Move around the right front wheel; check that all 30. When checking the coolant level in the radiator, lugs/wedges are in place and tight. use the coolant level sight gauge. If it is neces- sary to remove the radiator cap, relieve coolant 24.
Page 39: Engine Start-Up Safety Practices
ENGINE START-UP SAFETY PRACTICES 4. The key switch is a three position (OFF, RUN, START) switch. When the switch is rotated one position clockwise, it is in the RUN position and all electrical circuits (except START) are acti- vated. a. Turn key switch to the RUN (not START) Never attempt to start the engine by shorting position.
Page 40: After Engine Has Started
AFTER ENGINE HAS STARTED 3. DO NOT allow unauthorized personnel to ride in the truck. DO NOT allow anyone to ride on 1. Become thoroughly familiar with steering and the ladder or outside of the truck cab. Passen- emergency controls. After the engine has been gers must be belted into the passenger seat started, do not accelerate engine speed or during travel.
Page 41: Machine Operation On The Haul Road
3. Check gauges and instruments frequently dur- 4. Before traveling in reverse, give a back-up sig- ing operation for proper readings. nal of three blasts on the horn. Before starting forward, signal with two blasts on the horn. 4. Observe all regulations pertaining to the job These signals must be given each time the site's traffic patterns.
Page 42: Starting On A Grade With A Loaded Truck
STARTING ON A GRADE WITH A LOADED LOADING TRUCK 1. Approach the loading area with caution. Remain at a safe distance while the truck Initial propulsion with a loaded truck should begin from a level surface whenever possible. There are ahead is being loaded.
Page 43 4. When the truck is stopped and in dump posi- Lowering The Dump Body tion, apply the brake lock and move the direc- (When dumping on flat ground): tional control lever to the NEUTRAL position. It is very likely when dumping on flat ground that the dumped material will build up enough to prevent the body from lowering.
Page 44: Sudden Loss Of Engine Power
SUDDEN LOSS OF ENGINE POWER Lowering The Dump Body If the engine suddenly stops, there is enough hydrau- (When dumping over a berm or into a crusher): lic pressure stored in the brake and steering accumu- 1. Move the hoist lever to the DOWN position and lators to allow the operation of the steering and brake release.
Page 45: Safe Parking Procedures
SAFE PARKING PROCEDURES d. Allow the engine to cool gradually by operat- ing at low idle for three to five minutes, or if The operator must continue to use safety precau- preferred, activate the five minute shutdown tions when preparing for parking and stopping the delay timer as described on the following engine.
Page 46: Delayed Engine Shutdown Procedure
DELAYED ENGINE SHUTDOWN 5. Turn the key switch counterclockwise to the PROCEDURE OFF position to cause the engine to stop when the timing sequence is complete. When the 1. Stop the truck out of the way of other traffic. engine stops, the hydraulic bleed-down timer Park on a level surface, free of overhead power will activate and the 24 VDC electric circuits will lines or other objects that could prevent raising...
Page 47: Emergency Steering System
EMERGENCY STEERING SYSTEM Testing Operation The truck is equipped with an emergency steering system in the event of a failure in the oil supply to the main steering system. The emergency steering sys- tem was designed to meet or exceed SAE J1511 and Ensure no one is near the front tires during this ISO 5010 standards.
Page 48: Disabled Truck Dumping Procedure
If necessary, momentarily hookup from the good truck. The disabled truck may place the hoist control in POWER UP until the be another Model 830E or a different Komatsu body is able to descend in FLOAT. Do not model.
Page 49: A03030 3/06 General Safety And Operating Instructions
Attachments for towing the 830E are available from 7. Release the disabled truck brakes and remove Komatsu distributors as follows: the blocking. Front Bumper Modification Kit - XK0309: This kit con- 8. Sudden movement may cause tow bar failure.
Page 50 RESERVE ENGINE OIL SYSTEM (Optional) NOTE: Do not use the oil in the reserve tank to fill the engine sump. Both must be at proper level before The reserve oil tank for the engine is designed to add starting the engine. more oil capacity to the engine and to make less fre- 4.
Page 51 The plates and decals listed here are typical of this Komatsu model, but because of customer options, individual trucks may have plates and decals that are different from those shown here.
Page 52 Attached to the exterior of both battery compart- ments is a danger plate. This plate stresses the need to keep from making any sparks near the battery. When another battery or 24VDC power source is used for auxiliary power, all switches must be OFF prior to making any connections.
Page 53 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 key switch OFF and allow the engine to cool before removing the radiator cap. Unless the pressure is first released, removing the radiator cap after the engine has been operating for a time will result in the hot coolant being expelled from the radiator.
Page 54 These danger plates are mounted on the outside of each frame rail to alert technicians to read the warn- ing labels attached to the side of each of the accumu- lators (see below) prior to releasing internal nitrogen pressure or disconnecting any hydraulic lines or hardware.
Page 55 A warning plate is attached to the hydraulic tank to inform technicians that high pressure hydraulic oil is present during operation. When it is necessary to open the hydraulic system, Ensure the engine is stopped and key switch is OFF to bleed down hydraulic pressure.
Page 56 A decal plate is located on the frame near the left hoist cylinder. It provides the operator or technician with the hydraulic hook-up procedure before towing a disabled truck, by using a functional truck for hydrau- lic power. This warning decal is located below the battery dis- connect switches to warn personnel not to discon- nect the batteries during the first 90 seconds after turning the key switch off.
Page 57 This caution decal is placed near the battery discon- nect switches on the right side of the front bumper to alert servicing technicians that before doing any welding on the truck, always disconnect the battery charging alternator lead wire and isolate electronic control components before making welding repairs.
Page 58 this caution decal is placed on the back of the control cabinet to alert service technicians that this area con- tains capacitors and must not be disturbed in any manner. This information decal is placed on the outside of the door panel on the control cabinet wall that faces the right side of the operator cab.
Page 59 This decal is placed on the ground level engine shut- down switch which is mounted on the right side of the front bumper structure. It specifies that this switch is for emergency shutdown only. This page illustrates a variety of decals which are mounted on deck mounted cabinets, housings, and structures which must be lifted in a specific manner, and from specific points, in order to safely move or lift...
Page 60 (CL). The CL is used to verify the accuracy of the individual PIN. FC - Character positions 10 and 11 identify the Fac- tory Code (FC). The FC identifies the Komatsu fac- tory in charge of claims for the product. The FC for electric drive trucks is 61.
Page 61 The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P, Lubrication and Service, in this manual for more complete lubrication instructions. A04059 Warnings and Cautions A4-11...
Page 62 NOTES: A4-12 Warnings and Cautions A04059...
Page 63: Standard Torque Charts And Conversion Tables
On Fasteners and Standard Torque Values References throughout the manual to standard torques Komatsu does not recommend the use of special or other standard values will be to one of the following friction-reducing lubricants, such as Copper Coat, charts or tables.
Page 64 • Rust Preventive Grease - Code 312 from the Southwest Grease and Oil Company. NOTE: This list represents the current engineering approved sources for use in Komatsu manufacture. It is not exclusive. Other products may meet the same specifications of this list.
Page 65: Table V
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 lbs –...
Page 66: Table Vii
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 39.32...
Page 67: Table X
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 68 TABLE XIII COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS METRIC TO ENGLISH ENGLISH TO METRIC Multiply To Convert Multiply To Convert From From millimeter (mm) inch – in. 0.0394 inch – in. millimeter (mm) 25.40 centimeter (cm) inch – in. 0.3937 inch –...
Page 69: Storage Procedures
SECTION A7 STORAGE PROCEDURES INDEX STORAGE AND IDLE MACHINE PREPARATION ......... . 3 SHORT TERM IDLE PERIODS .
Page 70 NOTES A7-2 Storage Procedures A07006...
Page 71 STORAGE AND IDLE MACHINE PREPARATION There may be periods when it is necessary for a 1. Keep the vehicle fully serviced. machine to be idle for an extended period of time. 2. On a weekly schedule, perform a visual check Properly prepared, a stored machine may promptly of the vehicle, start and run the engine until both and safely be put back into operational service.
Page 72 PREPARATION FOR STORAGE Refer to Section P, Lubrication and Service, for the proper anti-freeze and conditioner concentrations. For long term idle periods, proper preparation will After refilling the system, always operate the engine pay large dividends in time and money when future until the thermostats open to circulate the solution operation of the vehicle is scheduled.
Page 73 13. Relieve tension from all drive belts. The engine 4. The cooling system should be completely manufacturer recommends insertion of heavy drained, chemically flushed, and refilled with a kraft paper between belts and pulleys to prevent conditioned water/antifreeze solution suitable sticking.
Page 74 11. Install fully charged batteries in unit. Clean con- 18. Use the Operation and Maintenance Manual for nectors and connect battery cables. Compart- guidance on engine start and vehicle checkout. ment must be free of corrosion. Secure Make a thorough check of all hose and line con- batteries with hold downs.
Page 75 RECONDITIONING AN IDLE VEHICLE 3. Inspect tires thoroughly for tread and side wall condition, weathering, cuts and cracks. a. Any tire suspected of being unserviceable should dismounted thoroughly inspected inside and out before being inflated. Never attempt operation of a vehicle which has been standing idle for a long period until all sys- tems which affect steering, brakes, engine, trans- mission and running gear have been completely...
Page 76 5. The vehicle engine should be inspected and a. Check all transmission electrical connections serviced according to the Engine Manufac- for corrosion, cleanliness and tightness. turer's Operation And Maintenance Manuals. Check electrical cables for weathering, dam- age and proper clamping. a.
Page 77 ENGINE OPERATION c. Check all hydraulic components - pumps, valves and cylinders for damage and corro- sion. Secure all mountings and connections. Control valves in the cab must be free mov- ing with no binding. d. Check exposed portions of all hydraulic cyl- Insure that all tools and loose equipment have inder rams for rust, pitting and corrosion.
Page 78 4. While the engine is warming up, check the engine and related components for any leaks. 3. Check gauges, warning lights and instruments Check the hydraulic pump for leakage as well before moving the machine to insure proper as all hydraulic lines. system operation and proper gauge functioning.
Page 79 ENGINE STORAGE Engine Storage-(Short Term) 11. Disconnect the electrical wiring from the fuel 1 Month to 6 Months pump solenoid. This procedure describes the proper method for the 12. Turn the fuel pump manual shutoff valve coun- short term storage of an engine. terclockwise until it stops.
Page 80 Engine Storage- (Long Term) 6 Months to 24 Months This procedure describes the proper method for the long term storage of an engine. Put a WARNING tag on the engine. The tag must indicate: Prepare the Engine for Long Term Storage •...
Page 81 ELECTRIC DRIVE TRUCKS Storage Instructions and Procedures Placing Equipment Into Storage This instruction provides the recommended proce- Perform the following instructions when preparing dures for protecting equipment from damage during General Electric equipment for storage. There are both short-term and long-term storage periods and three main equipment categories to consider: for maintaining adequate protection while in storage.
Page 82 When Storing A Truck That Is Not Operational When a truck which is not fully operational is being stored for a period of any length, perform the follow- Do not operate trucks without oil in the Motorized ing: Wheel gear cases. 1.
Page 83 Periodic Inspections amount oil to be used. This oil should be drained and new oil should be added after 500 It is important that periodic inspections (every three hours of operation. months) of stored equipment be performed to insure 5. Clean all Motorized Wheel grease fittings in the the continued serviceability of all protective mea- axle box.
Page 84 12. Perform a start-up procedure on the complete system to insure maximum performance during service. Refer to the truck's Vehicle Test Instructions for the complete test procedure. For The First Hour After all storage protection has been removed, the truck has been cleaned and inspected and repairs made as necessary, the Motorized Wheel gear case has been filled with new oil, the dirt seals have been completely purged with new grease and the system...
Page 85 TRANSMISSION PRESERVATION AND 5. Continue running the engine at 1500 rpm with the transmission in neutral until normal operat- STORAGE ing temperature is reached. Storage, New Transmission (Prior to installation). New transmissions are tested with preservative oil and drained prior to shipment. The residual oil remaining in the transmission pro- vides adequate protection to safely store the trans- If the unit does not have a converter-out tempera-...
Page 86 NOTES A7-18 Storage Procedures A07006...
Page 87: Structures
SECTION B STRUCTURES INDEX STRUCTURAL COMPONENTS ............B2-1 DUMP BODY .
Page 88 NOTES: B1-2 Index B01022...
Page 89 SECTION B2 STRUCTURAL COMPONENTS INDEX STRUCTURAL COMPONENTS ............B2-3 Preparation .
Page 90 NOTES: B2-2 Structural Components B02029...
Page 91 STRUCTURAL COMPONENTS The 830E deck components are removable in sec- tions as shown in Figure 2-1. The following removal and installation instructions detail the steps to be taken before the decks and hood can be removed. Additional steps may be required before the deck or The anti-slip material on the decks should be another major structure is removed, depending on inspected and maintained for the safety of all per-...
Page 92 LADDERS A diagonally mounted ladder (7, Figure 2-1) provides The diagonal ladder must be removed from the truck an easy and safe path for the operator to mount and if it becomes necessary to remove the radiator or the dismount the truck. In addition, a vertical ladder (6) is complete power module for major repairs.
Page 93 Removal 1. Shut down engine following all the procedures listed on page B2-3 in this section of the man- ual. 2. Open battery disconnect switch at the battery Before performing deck removal or repairs, box on the front bumper. ensure the battery disconnect switch is open and 3.
Page 94 LEFT DECK 4. Attach overhead hoist to lifting eyes on grid package (3). Removal 5. Remove hardware attaching grid package to the deck, lift assembly off deck and move to NOTE: The left deck mounting arrangement is nearly storage or work area. identical to the right deck.
Page 95 CENTER DECK Installation Center deck removal only requires removal of any Repeat above procedures in reverse order for instal- attached hoses cables etc. before removing the lation of the deck and components. Tighten all mounting hardware and lifting the deck structure off. attaching hardware to standard torque specifications as listed in Section A, Standard Torque Chart and Follow...
Page 96 NOTES: B2-8 Structural Components B02029...
Page 97 SECTION B3 DUMP BODY INDEX DUMP BODY ..............B3-3 Removal .
Page 98 NOTE: B3-2 Dump Body B03025...
Page 99: Dump Body
2X the weight being lifted. both pins (2). When in doubt as to the weight of components or any assembly procedure, contact the Komatsu area representative for further information. Lifting eyes and hooks should be fabricated from the proper materials and rated to lift the load being placed on them.
Page 100: Installation
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. Lifting eyes and hooks should be fabricated from the proper materials and rated to lift the load being placed on them.
Page 101: Body Pads
BODY PADS 4. If not already installed, install retainer (1) and cap screws (2) to hold bushing (12) in place. It is not necessary to remove the dump body to Tighten cap screws to 55 N·m (40 ft lbs) replace body pads. Pads should be inspected during torque.
Page 102: Adjustment
Adjustment 4. If pad contact appears to be unequal, repeat the above procedure. 1. Truck must be parked on a flat, level surface for inspection. 2. All pads, except the rear pad on each side, should contact the frame with approximately equal compression of the rubber.
Page 103: Body Guide
BODY GUIDE BODY-UP RETENTION CABLE 1. Body guide wear points should be inspected each time a body pad inspection is performed. (Refer to Figure 3-5.) The body guide should be centered between the wear plates (3), with a maximum gap of 4.8 mm (0.19 in.) at each side when new.
Page 104: Body Position Indicator
BODY POSITION INDICATOR The Body Position Indicator is a device mounted on the canopy of the dump body. When the body is low- ered, the indicator is visible to the operator. This device should be inspected daily and repairs made if required.
Page 105: Hoist Limit Switch
HOIST LIMIT SWITCH BODY UP SWITCH Refer to Section D, Electrical System (24VDC) for Refer to Section D, Electrical System (24VDC) for adjustment procedure of the hoist limit switch. adjustment procedure of the body up switch. B03025 Dump Body B3-9...
Page 106 NOTES: B3-10 Dump Body B03025...
Page 107 SECTION B4 FUEL TANK INDEX FUEL TANK ..............B4-3 Removal .
Page 108 NOTES B4-2 Fuel Tank B04026...
Page 109: Fuel Tank
FUEL TANK Removal Installation 1. Raise truck body and install body safety cables. 2. Drain sediment from tank and dispose of prop- erly. Drain remainder of fuel into clean contain- ers. The weight of the empty fuel tank is approxi- 3.
Page 110 FIGURE 4-1. FUEL TANK 1. Fuel Tank 8. Fuel Supply Hose 15. Flat Washer 2. Fuel Receiver Assembly 9. Fuel Gauge Sender 16. Rubber Dampener 3. Mounting Cap 10. Drain Cock 17. Ground Wire 4. Cap Screw 11. Hoist Circuit Filter Assemblies 18.
Page 111: Repair
FUEL GAUGE SENDER Repair Fuel gauge sender (9, Figure 4-1) is mounted on the If a tank has been damaged and requires structural side of the tank provides an electrical signal to oper- repair, perform such repairs before final cleaning. ate the fuel gauge on the instrument panel.
Page 112: Fuel Tank Breather Valve
FUEL TANK BREATHER VALVE NOTE: The relief pressure of the fuel tank breather valve is 70 - 89 kPa (10 - 13 psi). Disassembly 1. Remove clamp (3, Figure 4-2), cover (2) and screen (1). 2. Remove ball cage (10), solid ball (11) and float balls (12).
Page 113 SECTION C ENGINE INDEX POWER MODULE..............C2-1 COOLING SYSTEM .
Page 114 NOTES C1-2 Index C01029...
Page 115 SECTION C2 POWER MODULE INDEX POWER MODULE ..............C2-3 PREPARATION .
Page 116 NOTES: C2-2 Power Module C02027...
Page 117 POWER MODULE The radiator, engine and alternator/blower assem- 4. It is not necessary to remove the grille or radia- blies are mounted on a roller equipped subframe tor prior to the removal of the power module. If which is contained within the truck's main frame and radiator removal is desired or if only radiator is referred to as a “Power Module”.
Page 118 d. Attach hoist to lifting eyes on blower inlet 4. Disconnect all (already marked) electric, oil and duct assembly. Remove hardware attaching fuel lines that would interfere with power mod- duct to main alternator inlet. Remove hard- ule removal. Cover or plug all lines and their ware attaching upper duct mounts to electri- connections to prevent entrance of dirt or for- cal cabinet.
Page 119 14. Remove cap screws and washers securing cover (10, Figure 2-4) to grille at center of front bumper and remove. Remove cap screws and lockwashers (9) securing front subframe sup- port to main frame. Install safety chain around the front engine sub- frame cross member and main frame to prevent the power module from rolling forward when the subframe rollers are installed.
Page 120 19. Disconnect hydraulic pump drive shaft (1, Fig- 20. Attach hoist to lift points (2, Figure 2-4) at ure 2-4) at the drive shaft U-joint companion engine/alternator cradle structure. Raise the flange. rear portion of engine subframe and install sub- frame rollers (Refer to Figure 2-5).
Page 121 21. Reposition hoist to front subframe lifting points 22. Roll the power module forward sufficiently so (8, Figure 2-4). Raise the engine subframe until that adequate clearance is provided for the lift- the engine is on a level plane. Remove the ing device to be attached to the engine/alterna- safety chain.
Page 122 24. 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 for disassembly. For further disassembly of the engine, alternator, and radiator, refer to the appropriate section of this man- ual.
Page 123 7. Place stands or blocking under front of sub- 17. Install the rear subframe mounting caps (3) and frame to support assembly while repositioning secure caps in place with lubricated cap screws hoist. (4). Tighten cap screws to 551 ±21 N·m (407 ±15 ft lbs) torque.
Page 124 31. Install air intake duct supports (2, Figure 2-3). c. Ensure the battery disconnect switches are Install engine air intake ducts (3). Position in the OFF position. Inside the battery box, adjusters of adjacent T-bolt clamps 180° apart. connect both battery negative ground cables Clamp the ducts securely to ensure a positive to the battery posts.
Page 125 SECTION C3 COOLING SYSTEM INDEX COOLING SYSTEM DESCRIPTION ..........C3-3 RADIATOR .
Page 126 NOTES: C3-2 Cooling System C03035...
Page 127 A second, “high temperature” core (3), located at the rear of the radiator assembly is used for the engine The standard 830E engine is a Komatsu model coolant circuit. In this circuit, the engine water pump SDA16V160 single stage turbocharged engine (10) circulates coolant through the engine block (9) equipped with aftercoolers.
Page 128 RADIATOR 4. Disconnect surge tank vent hoses and electrical cable attached to coolant level probe (6). Removal Remove clamps (5) securing hoses and electri- cal cables to fan shroud, tubes and support 1. Place battery disconnect switch in the OFF rods.
Page 129 NOTE: The system is charged with HFC-134A refrigerant. 8. After system is evacuated, remove hoses from condenser and cap all openings to prevent con- Federal regulations prohibit venting air condi- tamination. Unclamp hoses and remove from tioning system refrigerants into the atmosphere. radiator area to prevent interference when radi- An approved recovery/recycle station must be ator is removed.
Page 130 9. Remove fan guard (2, Figure 3-4) from shroud: 14. Remove hardware attaching grille structure to radiator assembly, attach overhead crane, and a. Guard can be completely removed from the lift slightly. Move grille structure forward to clear truck by separating the halves and removing. radiator assembly.
Page 131 Installation 9. Position fan guard against shroud and tighten mounting hardware to 55 N·m (40 ft lbs) 1. Reinstall shroud (1, Figure 3-4), air conditioner torque. (If halves of guard were disassembled, condenser, and fuel cooler. Install air condi- tighten cap screws clamping halves together to tioner receiver/drier (10) if removed.
Page 132 Radiator Filling Procedure Cooling System is pressurized due to thermal expansion of coolant. DO NOT remove radiator cap while engine and coolant are hot. Severe burns may result. 1. With engine and coolant at ambient tempera- ture, remove radiator cap. Note: If coolant is added using the Wiggins quick fill system, the radiator cap MUST be removed prior to adding coolant.
Page 133 REPAIRING THE RADIATOR Pressure washers should not exceed 8275 kPa (1200 psi). Unlike conventional cores, the spray Radiator service is a specialized function usually not nozzle can be used right up next to the core. Starting accomplished by most maintenance shops. The from the air exit side, place the high pressure washer large size and weight of the off-road truck radiators nozzle next to the fins.
Page 134 Cleaning and Inspection 1. Use a drill with a 19 mm (3/4 in.) wire brush to remove any foreign material from the tube holes, then wipe the holes clean. 2. Clean the inside of the tanks and tubes. In most cases, just flushing the inside with soap and a high pressure hot water washer will be sufficient.
Page 135 5. Working from the front of the radiator (opposite of fan side), install the bottom row of tubes starting with the fan side row. When installing the tubes, center the top of the tube in the top seal while angling the tube only as much as necessary.
Page 136 COOLANT SYSTEM Pressure Testing TROUBLESHOOTING The radiator should be pressure tested at 103 kPa (15 psi) for 30 minutes. Various methods of pressure If abnormal coolant temperatures are experienced, testing include the following: perform the following visual inspections and tests: •...
Page 137 ALTERNATOR REMOVAL PROCEDURE ......... . C4-3 Removal (Komatsu SSDA16V160 or SDA16V160 Engine) ......C4-3 ENGINE/ALTERNATOR MATING .
Page 138 NOTES: C4-2 Power Train C04034...
Page 139: Alternator Removal Procedure
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 mod- ule has been removed from the truck. (Refer to Fig- ure 4-2.) When lifting alternator, attach hoist to lift eyes only.
Page 140 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 CAP SCREWS 1. Engine Barring Tool 3. Flywheel Housing 2. Access Hole 4.
Page 141: Engine/Alternator Mating
(CW), or counterclockwise (CCW), is the direc- “Measurement C”:_________________________ tion of rotation when looking at the front (damper end) of engine. • Crankshaft end-play for Komatsu SSDA16V160 or SDA16V160 Engine: 0.13 - 0.38 mm (0.005 - 0.015 in.). SERVICE DATA - Eccentricity & Runout Limits Description T.I.R.
Page 142 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 cap screw (4) at each end into the alter- nator housing (1). Leave cap screws finger- tight.
Page 143: Joining Alternator And Komatsu Ssda16V160 Or Sda16V160 Engine
Joining Alternator and Komatsu SSDA16V160 or 8. Compare the step 7 value to the measurement SDA16V160 Engine taken before alternator was installed on engine. When lifting alternator, attach hoist to lift eyes only. The alternator weighs approximately 4037 kg (8,900 lbs). Use a lifting device that can handle the load safely.
Page 144: Engine
ENGINE 9. Rotate the crankshaft one full revolution and lis- ten for any unusual noise caused by moving Removal components contacting stationary parts. 10. Install engine sidecover, if removed. Install lock- Refer to instructions in previous sections for removal wire on all alternator mounting cap screws. instructions for the Power Module, alternator, and radiator assembly.
Page 145: Service
Service 2. Install alternator on engine following instruc- tions for “Engine/Alternator Mating”. Complete instructions covering the disassembly, 3. Tighten rear engine mounting cap screws (2) to assembly and maintenance of the engine and its 465 N·m (345 ft lbs) torque after alternator is components can be found in the engine manufac- installed.
Page 146 NOTES: C4-10 Power Train C04034...
Page 147 SECTION C5 AIR CLEANERS INDEX AIR CLEANERS ..............C5-3 OPERATION .
Page 148 NOTES: C5-2 Air Filtration System C05019...
Page 149: Air Cleaners
AIR CLEANERS OPERATION SERVICING THE AIR CLEANERS Air required by the diesel engine passes through the air cleaner assemblies mounted on each side of the radiator. These air cleaners discharge heavy particles of dust and dirt by centrifugal action and then remove finer particles by passing air through The engine must be turned off before servicing filter cartridges.
Page 150: Replacing The Filter Element
Replacing The Filter Element 3. Inspect the main filter element carefully for damage, holes or breaks which might affect NOTE: The function of the safety filter is to increase reuse of the element. If the element appears overall reliability and engine protection. If the safety serviceable, proceed with...
Page 151: Air Cleaner Assembly Cleaning
AIR CLEANER ASSEMBLY CLEANING Main Filter Cleaning Have a new safety (secondary) filter element on hand before removing the used filter element. Do not keep the intake system open to the atmosphere any longer than necessary. Only the main filter elements may be cleaned, 5.
Page 152 4. After cleaning, inspect the element thoroughly Clean dust loaded elements with dry filtered for the slightest ruptures and damaged gaskets. compressed air as follows: A good method for detecting paper ruptures is 1. Maximum nozzle pressure must not exceed to place a light inside the filter element, as 207 kPa (30 psi).
Page 153: Precleaner Section Cleaning
Precleaner Section Cleaning NOTE: The precleaner section may be separated from the air cleaner assembly without removing the The tubes in precleaner section (2, Figure 5-1) entire air cleaner from the truck. should be cleaned at least once per year and at each 1.
Page 154: Air Intake Troubleshooting
AIR INTAKE TROUBLESHOOTING To insure maximum engine protection, be sure that all connections between air cleaners and engine intake are tight and positively sealed. If air leaks are suspected, check the following: 1. All intake lines, tubes and hump hoses for breaks, cracks, holes, etc., which could allow an intake air leak.
Page 155 SECTION C7 FAN CLUTCH INDEX REMOVAL & INSTALLATION TOOLING ..........C7-3 DISASSEMBLY.
Page 156 NOTES C7-2 Fan Clutch C07001...
Page 157: Removal & Installation Tooling
FAN CLUTCH REMOVAL & INSTALLATION TOOLING TOOL FRONT SLEEVE BEARING TOOL REAR SLEEVE BEARING C07001 Fan Clutch C7-3...
Page 158 TOOL C - FRONT AND REAR SLEEVE BEARING REMOVER TOOL D - WEAR SLEEVE AND RETAINER/SEAL ASSEMBLY INSTALLER; BEARING REMOVER; ASSEMBLY PUSHER TOOL C7-4 Fan Clutch C07001...
Page 159 TOOL E - BEARING INSTALLER TOOL F - BEARING INSTALLER C07001 Fan Clutch C7-5...
Page 160: Disassembly
DISASSEMBLY FIGURE 7-1. FAN CLUTCH EXPLODED VIEW 1. Orifice Fitting 16. External Snap Ring (Spacer) 32. Internal Snap Ring 2. Dowel Pin (Rear) 17. Seal Ring (Hook-Type) 33. Main Bearing (Front) 3. Pitot Tube 18. Bolt 34. O-Ring Seal 4. Wear Sleeve 19.
Page 161 FIGURE 7-1. FAN CLUTCH CUTAWAY (Typical) 3. Pitot Tube 14. Main Bearing 27. External Snap Ring 37. Washer 4. Wear Sleeve 15. Internal Snap Ring 28. External Snap Ring 38. Bolt 5. Retainer/Seal 16. External Snap Ring 29. Clutch Hub 39.
Page 162 FIGURE 7-4. FIGURE 7-2. 3. Remove O-ring seal (34). 1. Support the fan clutch on a bench with fan mounting hub (42) facing upward. Support the assembly beneath the pulley. Remove bolts (38) and washers (37). FIGURE 7-5. FIGURE 7-3. 2.
Page 163 FIGURE 7-8. FIGURE 7-6. 7. Remove front oil seal (36). 5. Remove clutch hub (29). FIGURE 7-9. FIGURE 7-7. 8. Remove internal snap ring (32). 6. Position the sub-assembly beneath the ram of a press. Support the assembly beneath the bearing retainer as close as possible to fan mounting hub (42).
Page 164 FIGURE 7-10. FIGURE 7-12. 11. Remove front retainer/seal assembly (40). 9. Turn bearing retainer (35) over on the press Wedge a large chisel or other appropriate tool bed. Press front bearing (33) out of the bearing behind the retainer to force it off fan mounting retainer using tooling (D).
Page 165 FIGURE 7-14. FIGURE 7-16. 12. Inspect sleeve bearing (44) and sleeve bearing (41). Compare the color of each bearing to the chart above. The lighter the appearance of the 14. Remove the stack of facing plates (30) and bearing, the more worn it is. If either bearing steel clutch plates (31) from inside the pulley.
Page 166 FIGURE 7-20. FIGURE 7-18. 18. Support beneath the pulley to prevent it from dropping to the bench. Remove bolts (9) and 16. Attach wire lifting hooks to piston (23). Use the lockwashers (8). lifting hooks to pull the piston from pulley adapter (21).
Page 167 FIGURE 7-22. 20. Position the shaft as shown. Insert a phillips- FIGURE 7-24. head screwdriver into pitot tubes (3) to loosen and remove them from the shaft. Rotate the pitot tube until the sealant holding it tight is broken loose. Then grip the pitot tube with a 22.
Page 168 FIGURE 7-28. FIGURE 7-26. 26. Use tooling (E) to press rear bearing (14) out of rear bearing retainer (11). 24. Support the bearing retainer as close as possible to the bearing bore. Be careful not to damage the retainer/seal assembly. Press the shaft out of bearing (14) using tooling (E).
Page 169 FIGURE 7-30. 28. Remove rear retainer/seal assembly (5). Drive the assembly off the shaft or wedge a large chisel or other appropriate tool behind the retainer to force it off. C07001 Fan Clutch C7-15...
Page 170: Cleaning And Inspection
CLEANING AND INSPECTION Thoroughly clean all components before inspection. Check each of the following components, and follow the guidelines for reuse: • Ball bearings - Replace at time of rebuild. • Internal snap rings - Must not be damaged or worn. Must be flat and have square edges at outer diameter. •...
Page 171 FIGURE 7-32. 3. Check pulley and adapter dimensions. FIGURE 7-34. 5. Check piston (23) dimensions. FIGURE 7-33. 4. Check rear bearing retainer (11) dimensions. C07001 Fan Clutch C7-17...
Page 172 FIGURE 7-35. PISTON REWORK (For earlier pistons with the drilled orifice.) 6. Check the piston for a drilled orifice at the inside face. If the piston contains the orifice, modify the piston as shown in Figure 7-35. 7. Inspect clutch hub (29) for wear. Wear marks that may be present on the teeth must not restrict plate movement.
Page 173 FIGURE 7-37. 11. Inspect front bearing retainer (35). 12. Inspect end cap (45) for any wear or raised nicks. C07001 Fan Clutch C7-19...
Page 174: Assembly
ASSEMBLY 2. If removed, install dowel pin (43) into fan NOTE: The fan clutch is reassembled using Loctite ® mounting hub assembly (42). Refer to Figure 7- (or equivalent) sealants. Follow manufacturer's 38. Press the pin into the hub, leaving 2.3 mm recommendations regarding minimum cure time to (0.090 in.) exposed.
Page 175 FIGURE 7-40. FIGURE 7-42. 4. Turn the hub over on the bed of the press. Using tooling (B), press rear sleeve bearing (41) into the fan mounting hub until the tool contacts the shoulder of the hub. FIGURE 7-41. 3. Using tooling (A), press front (long) sleeve bearing (44) into the fan mounting hub until the tool contacts the shoulder of the hub.
Page 176 FIGURE 7-44. FIGURE 7-43. 5. Press front retainer/seal assembly (40) onto the fan mounting hub (42) using tooling (D). The inner race of the retainer should be recessed 1.0 mm (0.040 in.) below the shoulder. Check carefully to ensure that the retainer/seal assembly is installed straight and is not bent or damaged in any way which will cause interference between it and the bearing retainer...
Page 177 FIGURE 7-46. FIGURE 7-48. 7. Coat the bore of the fan mounting hub (42) with 9. Install internal snap ring (32). a thin coating of Loctite Primer N and #242. Remove frozen end cap (45) from the freezer. Do not apply Loctite to the end cap. Press the end cap into the hub until the cap bottoms out.
Page 178 FIGURE 7-50. 11. Coat the inside diameter of the bearing and the fan mounting hub bearing journal with Loctite Primer N and #609 (or equivalent). Place the FIGURE 7-51. front bearing retainer sub-assembly into position on the fan mounting hub. Ensure the notch in the bearing is aligned with the bearing 12.
Page 179 FIGURE 7-53. FIGURE 7-55. 15. Use tooling (D) to press rear retainer/seal assembly (5) onto shaft (6). The inner race of the retainer should be recessed 1.0 mm (0.040 in.) below the shoulder. Check carefully to ensure that the retainer/seal assembly is installed straight and not bent or damaged in any way which will cause interference between it and the bearing retainer...
Page 180 FIGURE 7-57. FIGURE 7-56. 17. Coat the outside diameter of rear bearing (14) and the mating surface of bearing retainer (11) with Loctite Primer N and #609 or equivalent. The end of the bearing with the notch is installed first. Using tooling (F) or equivalent, press the bearing into the bearing retainer.
Page 181 FIGURE 7-59. 19. Some fan clutches were assembled with an external snap ring that is used as a spacer between the bearing and the oil seal. Newer models were assembled using a notched spacer. If an external snap ring was used, place snap ring (12) on top of the bearing (oil seal side).
Page 182 FIGURE 7-62. FIGURE 7-63. 23. Install external snap ring (16). Ensure that the snap ring is fully seated in the groove. It may be 22. Place the shaft sub-assembly on the press bed. necessary to tap on the snap ring with a Coat the inside diameter of the bearing and the screwdriver to fully seat it.
Page 183 Push the pitot tubes to the bottom of the hole. The outer end of the tube should be located well within the pulley-locating shoulder of the bearing retainer. Rotate the tube so the open, bent end faces in a counterclockwise direction and is exactly parallel to the surface of the bearing retainer.
Page 184 Do not push the piston in place. Forcing the piston will usually cause the seal rings to be cut. 28. Carefully place the piston in the pulley. Without pressing down on the piston, rotate it slowly back and forth until it falls into place. FIGURE 7-69.
Page 185 32. Turn the pulley adapter assembly over and install two lifting eyes 180 degrees apart. Install a guide bolt in one bolt hole of the pulley. Refer to Figure 7-71. Coat front O-ring seal (34) with petroleum jelly or an oil-soluble grease. Place the seal in the groove in the pulley.
Page 186 FIGURE 7-76. FIGURE 7-74. 36. Install bolts (9) with lockwashers (8). Tighten each bolt to 49 - 58 N•m (36 - 43 ft lbs). 34. Lubricate O-ring seal (13) with petroleum jelly or an oil-soluble grease and install it in the pulley groove.
Page 187 FIGURE 7-78. 38. Turn the assembly over on the bench. Install remaining bolts (38) and lockwashers (37). Tighten each bolt to 49 - 58 N•m (36 - 43 ft lbs). C07001 Fan Clutch C7-33...
Page 188: Test Procedure
TEST PROCEDURE 1. The fan clutch should be fully locked up with 275 kPa (40 psi) oil pressure supplied at the control pressure port. 2. Operate the fan clutch with 82° C (180° F) oil supplied to the “oil in” port for 2 hours. Manually engage and disengage the clutch during the test to operate seals in both modes.
Page 189 Prior to welding on the truck, maintenance personnel should attempt to notify the Komatsu • Factory Representative. The welding ground electrode should be attached as close as possi- ble to the area to be welded.
Page 190 TRUCK SHUTDOWN PROCEDURE 1. Reduce the engine speed to idle. Place the directional control lever in PARK. Make sure that the parking brake applied indicator light in the overhead panel is illuminated. 2. Place the drive system in the rest mode by turning the rest switch on the instrument panel ON. Make sure that the rest mode indicator light is illuminated.
Page 191 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 24VDC ELECTRIC SUPPLY SYSTEM ..........D2-3 ELECTRICAL SYSTEM DESCRIPTION .
Page 192 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT ......D2-9 24 VDC ELECTRIC START SYSTEM ..........D2-11 CRANKING MOTORS .
Page 193 24VDC ELECTRIC SUPPLY SYSTEM ELECTRICAL SYSTEM DESCRIPTION The truck uses a 24VDC electrical system which sup- plies power for engine starting circuits and most non- propulsion electrical components. 24VDC engine starting circuit is supplied by four heavy duty, DO NOT SMOKE or allow flame around a dead Type 8D, 12-volt storage batteries.
Page 194 To remove corrosion, clean the battery with a solu- The rate of self-discharge of a battery kept at 38°C tion of ordinary baking soda and a stiff, non-wire (100°F) is about six times that of a battery kept at brush and flush with clean water. Make sure that 10°F (50°F), and self-discharge of a battery kept at none of the soda solution is allowed to enter the bat- 27°C (80°F) is about four times that one at 10°F...
Page 195 BATTERY SUPPLY SYSTEM A 24VDC to 12VDC converter, located toward the bottom of the inside left wall of the auxiliary control 24VDC Battery Charging Alternator cabinet, is used to convert the 24 volt battery system voltage to 12 volts for various truck components. Refer to Section D, Battery Charging Alternator in, for service information regarding the battery charging When maintenance or repairs are performed, the...
Page 196 Battery Control Box 24VDC to 12VDC Converter Battery control box (4, Figure 2-1) is located to the 24VDC to 12VDC converter (1, Figure 2-2) is used to left of the battery box. This box contains the battery convert the 24 volt battery system voltage to 12 volts disconnect switches and other components listed for various truck components such as the radio/cas- below.
Page 197 Operation SYSTEM (WITH PRELUBE) The prelube system is activated when the operator The Komatsu SDA16V160 engine includes an turns the key switch and holds it in the “start” posi- engine pre-lubrication system designed to reduce tion. This allows the current to flow to the prelube wear due to dry starts.
Page 198 MAINTENANCE Pressure Switch Prelube system maintenance should be performed The pressure switch (2, Figure 2-3) is a 17.2 kPa (2.5 annually or at 5000 hour intervals as described psi), normally closed (N.C.) switch, located so that it below. can sense oil pressure after the engine oil has passed through the filters.
Page 199 TROUBLESHOOTING PRELUBE CRANKING MOTOR 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 17.2 kPa (2.5 psi).
Page 200 Problem Probable Cause • Cranking motor 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 201 Note: When a Komatsu SDA16V160 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 cranking motors actuate.
Page 202 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 key switch, magnetic switches, solenoids and cranking motor(s).
Page 203 Interpreting Results of Tests Disassembly 1. Rated current draw and no-load speed indi- The cranking motor should be disassembled only as cates normal condition of the cranking motor. far as necessary to repair or replace defective parts. 2. Low free speed and high current draw indi- 1.
Page 204 Cleaning and Inspection 1. The drive (71), armature (45) and fields (46) FIGURE 2-6. CRANKING MOTOR ASSEMBLY should not be cleaned in any degreasing tank, 1. C.E. Frame 51. O-ring or with grease dissolving solvents, since these 2. Washers 52. Inspection Plug would dissolve the lubricant in the drive and 3.
Page 205 FIGURE 2-6 CRANKING MOTOR ASSEMBLY D02034 24 VDC Electric Supply System D2-15...
Page 206 Armature Servicing 3. Grounds in the armature can be detected by the use of a 110-volt test lamp and test points. If the If the armature commutator is worn, dirty, out of lamp lights when one test point is placed on the round, or has high insulation, the armature (45, Fig- commutator with the other point on the core or ure 2-6) should be put on a lathe and the commutator...
Page 207 5. To check for grounds, move battery lead from “G” (Figure 2-8) and from “MTR” (Figure 2-9) to the solenoid case. Ammeter should read zero. If not, the winding is grounded. FIGURE 2-7. SIMPLIFIED SOLENOID CIRCUIT SOLENOID CHECKS A basic solenoid circuit is shown in Figure 2-7. Sole- noids can be checked electrically using the following procedure.
Page 208 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 209 MAGNETIC SWITCH The magnetic switch is a sealed unit and not repair- able. FIGURE 2-11. CHECKING PINION CLEARANCE FIGURE 2-12. MAGNETIC SWITCH ASSEMBLY Removal Pinion Clearance 1. Remove battery power as described in Crank- To adjust pinion clearance, follow the steps listed ing Motor Removal.
Page 210 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 211 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 24 VDC ELECTRICAL SYSTEM COMPONENTS ........D3-3 TRUCK SHUTDOWN PROCEDURE .
Page 212 BODY-UP SWITCH ............D3-15 Operation .
Page 213 24 VDC ELECTRICAL SYSTEM COMPONENTS AUXILIARY CONTROL CABINET COMPO- NENTS The following 24VDC electrical system components are located in the auxiliary control cabinet, which is mounted on the left side of the main control cabinet Do not attempt repairs until the truck is properly behind the cab.
Page 214 5 Minute Idle Timer Test the 5 minute idle timer circuits as follows: 1. With the key switch ON, press the engine shut- 5 minute idle timer (4) is activated when the operator down switch firmly to the momentary position presses the 5 minute idle timer engine shutdown and release (switch will return to the ON posi- switch on the instrument panel.
Page 215 FIGURE 3-1. AUXILIARY CONTROL CABINET - LEFT WALL 1. 24VDC Terminal 7. 12V Power Relay 13. Relay Board - RB5 2. 12VDC Terminal 8. Control Power Relay 14. Relay Board - RB6 3. Engine Starter Failure Delay Timer 9. Auto Lube Timer 15.
Page 216 Diode Board - DB1 If a diode failure is suspected, remove and check the diode as follows: Diode board (18, Figure 3-1) contains 24 replaceable 1. Grasp the diode connector, compressing the diodes that are mounted on a plug-in connector for locking “ears”...
Page 217 Fuse Blocks Alarm Indicating Device (AID) System Four fuse blocks (1, Figure 3-3) contain fuses that Alarm indicating device (AID) module (1, Figure 3-4 protect various circuits on the truck. Always replace a is connected to the electrical accessories circuits to blown fuse with a new one of the same rating.
Page 218 The AID system enables the indicating lights to be The following briefly describe each card and its func- flashing or constant. The AID also has the capability tion. Refer to Section R, Schematics, for the circuit of operating an audible alarm along with the light. components described below.
Page 219 Hot Switch Inverter (Not Used) Coolant Level & Flasher The coolant level and flasher card contains two sepa- The optional oil level card is used to turn on the low rate circuits. The flasher circuit at the top of the card oil level indicator light to warn the operator that the has Q12 transistor biased to be saturated when no engine oil/hydraulic tank oil level is below acceptable...
Page 220 RELAY BOARDS Relay Boards RB1, RB3, RB4, RB5 The auxiliary control cabinet contains eight relay Each relay board of this type is equipped with four boards to provide control for many of the 24VDC cir- green lights (9, Figure 3-6) and one red “breaker cuits.
Page 221 Relay Board RB6, RB7, RB8, RB9 To replace a circuit breaker: Relay boards 6, 7,8 and 9 (Figure 3-7) do not contain NOTE: Always replace a circuit breaker with one of circuit breakers or modular cards. Additional circuits the same amperage capacity as the one being may be added by utilizing a spare relay socket as removed.
Page 222 1. Relay Board 2. Screw 3. Screw 4. Circuit Breaker 5. Circuit Panel Card 6. Screw 7. Breaker Open Light (RED) 8. Bleed Down Light (GREEN) (Relay Board 4 Only) 9. K1, K2, K3, K4 Lights (GREEN) 10. Screw 11. Relay 12.
Page 223 Relay Board Functions Relay Board 4 (RB4) The following describes the components and func- 1 - Steering Pressure Bleed Down Timer Module tions of each relay board. card 1 - Bleed Down Light (Green): This light is illuminated when the bleeddown solenoid is Relay Board 1 (RB1) being energized.
Page 224 Relay Board 6 (RB6) The following relays are installed on RB6: Backup Lights & Horn Relay (K1) Engine Run/Ignition Relay (K2) Spare Relay (K3) Spare Relay (K4) Ether Start Relay (K5) 5 Minute Idle System (K6) 5 Minute Idle System (K7) 5 Minute Idle System (K8) FIGURE 3-7.
Page 225 BODY-UP SWITCH Adjustment Body-up switch (3, Figure 3-8) is located inside the Before adjusting the body-up switch, inspect the right frame rail near the front of the body. It must be body pads for wear and damage. Replace the body adjusted to specifications to ensure that the proper pads if required.
Page 226 HOIST LIMIT SWITCH Hoist limit switch (5, Figure 3-9) is located inside the right frame rail above the rear suspension, near the body pivot pin. The hoist limit switch is designed to stop the hoist cylinders before they reach full exten- sion, preventing possible damage to the dump body or hoist cylinders.
Page 227 FUSE BLOCK CHARTS FUSE BLOCK #1 LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT A/C, Heater Blower Motor Windshield Washer / Wiper Instrument Panel Gauges 712G Key Switch Power 712P Hoist Limit Solenoid 712H Turn Signal / Clearance Lights 712T Engine Options 712E AID and Indicator Lights Engine Start Failure 712SF...
Page 228 FUSE BLOCK #3 LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT Cab Drive System Automatic Lube Pump 68ES Interface Module 71IM Cab Drive Components 710S Right Front Wheel Speed Sensor 15RFWS Left Front Wheel Speed Sensor 15LFWS Cigarette Lighter R.H. Cab Window L.H. Cab Window FUSE BLOCK #4 LOCATION AMPS...
Page 229 CIRCUIT BREAKER CHART CIRCUIT BREAKERS LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT RB3 - CB11 12.5 Back Up Horn and Lights RB1 - CB13 12.5 Turn Signals / Clearance Lights 11CL RB1 - CB14 12.5 Turn Signal Flasher RB1 - CB15 12.5 Tail Lights RB3 - CB16 12.5...
Page 230 NOTES: D3-20 24VDC Electrical System Components 10/06 D03036...
Page 231 SECTION D10 BATTERY CHARGING ALTERNATOR INDEX BATTERY CHARGING SYSTEM ........... D10-5 BATTERY CHARGING SYSTEM .
Page 232 WIRING DIAGRAM ............D10-12 DIMENSIONS AND TORQUE VALUES .
Page 233 Stator Test 1: Check For Stator-To-Stator Continuity ......D10-25 Stator Test 2: Check For Grounded Stators ........D10-26 THERMAL SWITCH TEST .
Page 234 Drive End Bearing Installation ..........D10-64 Drive End Rotor Installation .
Page 235 BATTERY CHARGING SYSTEM BATTERY CHARGING SYSTEM ELECTRICAL SYSTEM DESCRIPTION The Komatsu truck utilizes a 24VDC electrical sys- tem which supplies power for all non-propulsion elec- Lead-acid storage batteries contain sulfuric acid, trical components. The 24VDC power is supplied by which if handled improperly, may cause serious two pairs of 12-Volt storage batteries wired in series.
Page 236 Troubleshooting NOTE: When washing the batteries, ensure the cell caps are tight, preventing any cleaning solution from The two most common problems that occur in the entering the battery cells. charging system are undercharging and overcharg- ing of the truck's batteries. Acid Levels Undercharging The addition of acid will be necessary if considerable...
Page 237 To offset the results of self-discharge, booster-charge idle batteries (not a quick charge) at least once every thirty days. Batteries not used for long periods in a discharged condition are attacked by a crystallization of the lead sulfate on the plates. Such batteries are called sulfated and are, in the majority of cases, irreparably damaged.
Page 238 BATTERY CHARGING ALTERNATOR This is a basic dual stator alternator constructed from shell assembly (8) containing one stator at each end and a field coil between the stators. GENERAL INFORMATION Drive end housing (9) and anti-drive end housing (6) General Description each contain a bearing to support drive and rotor The Niehoff model C653A 28-Volt (260 Amp) alterna- shaft (1).
Page 239 Terminal Identification and Location Regulator Harness Plug Identification FIGURE 10-3. PIN CONNECTION IDENTIFICATION Alternator Specifications Volts ....... . 28VDC Amps .
Page 240 Battery/Alternator Terminology Diode Trio: Assembly of three diodes, one diode connected to each stator phase tap. Used typically to NOTE: Charge voltage and amp rates vary from operate as a signaling source, once the alternator is battery type to battery type, based on battery rotating, to tell the regulator to turn on (self-energiz- construction technology and physical size of the ing signal), or to provide current for the field coil oper-...
Page 241 Set Point: The voltage value to which the regulator is set. The voltage value is established by the battery type and the vehicle duty cycle. There are four val- ues available on the regulator. The set point valve may be fixed (flat compensation) or variable, based on operating temperature (negative temperature compensation).
Page 242 WIRING DIAGRAM FIGURE 10-5. WIRING DIAGRAM D10-12 Battery Charging Alternator D10003 07/06...
Page 243 DIMENSIONS AND TORQUE VALUES FIGURE 10-6. TORQUE SPECIFICATIONS AND OVERALL DIMENSIONS TORQUE SPECIFICATIONS Item Description Metric Ground Bolt (B-), M10 X 1.5 15 N·m 11 ft lbs Pulley Nut, M20 X 1.5 163 N·m 120 ft lbs Output Bolt (B+), M12 X 1.75 32 N·m 24 ft lbs Fan Nut, M16 X 1.5...
Page 244 PERIODIC MAINTENANCE TESTING Alternator performance depends on the condition of GENERAL INFORMATION the components in the charging system. The most important components in the charging system are the Troubleshooting Alternator (On-Truck) alternator drive belt, battery, and related cables and Most 24-Volt charging system problems can be diag- connections.
Page 245 8. Check the battery. The batteries must be in NOTE: Until electrical system component good condition and fully charged. If any battery temperatures stabilize, the conditions listed here may condition is marginal, replace it with one known be observed during cold start voltage tests. to be in good condition.
Page 246 Test Set-up 1. Discharge the battery as follows: a. Disable the fuel system. b. Turn all lights and accessories on. Crank the engine for 10-15 seconds to discharge the battery. c. Turn all lights and accessories off. d. Enable the fuel system. 2.
Page 247 Test Procedure 2. Watch the meter reading(s). If the battery is suf- ficiently discharged, the amps must be high within ± 10% of the output specified by the per- formance curve. Volts must be within or below the normal range as the battery approaches full The following tests require working near the charge.
Page 248 REGULATOR TESTING 3. If the shaft is still not magnetized, remove the jumper from the alternator (D+) terminal on the Regulator Bypass Test (No Output) regulator and go to Step 4. 4. If the shaft is not magnetized: If the Troubleshooting Alternator test procedure indi- cates low or no output, perform the following test to a.
Page 249 6. Set the voltmeter to the diode test scale. a. Connect the black lead of the voltmeter to pin E in the wiring harness plug. b. Connect the red lead to the (B-) terminal on the alternator. Limit the time the terminal is connected to a few seconds.
Page 250 BENCH TESTING Bench Test 1: No-Load Test 1. With the battery connected and no electrical load, operate the alternator at 5000 rpm. 2. Compare the test results to the No Load Test, Table 10-5, and take the appropriate action, as Perform the following on-bench tests when: stated in the table.
Page 251 Bench Test 2: Full Load Test 2. Set up the load on the alternator the same as Bench Test 2. 1. With the load set to the rated output (listed on 3. Note whether the amps increased to within ± the nameplate) ±...
Page 252 STATIC TESTING Check For Shorted Power Transistor 1. Set the DMM to the diode test scale and zero the meter. Static tests must confirm on-vehicle and bench tests. For best results, disassemble the alterna- tor, as needed, to access the parts. Equipment •...
Page 253 Circuit Tests 3. The expected reading listed for each test must be obtained. 1. Before testing, check for visible signs of dam- 4. Replace any component that fails. aged components. 5. Remove wiring harness (1, Figure 10-12) 2. Conduct the tests described in Alternator Pin- before any test.
Page 254 FIELD COIL TESTS This test is used to check for an open or shorted field coil. Field Coil Test 1: Check for Open or Shorted Field Coil 1. Set the digital multimeter DMM to x1 scale. Ensure the DMM is zeroed. 2.
Page 255 STATOR TESTS 3. Move the drive lead from pin A (F-) to pin F (F+) in the harness plug. The DMM must show a These alternators have delta-wound stators. Test 1 very high resistance. If the ohmmeter shows will show the condition of the phase lead from the less than 100K ohms, the field coil is grounded.
Page 256 Stator Test 2: Check For Grounded Stators Initial Test 1. Set the DMM to the ohms scale and zero the 1. Disconnect the wiring harness plug from the meter. regulator. 2. Connect one DMM lead to the (B-) terminal on 2.
Page 257 Verifying a Faulty Thermal Switch 1. Remove the cover from the control box on the drive end housing. 2. Locate the thermal switch inside the control box. 3. Test the two wires from the thermal switch for continuity. a. If there is no continuity, the switch is faulty. b.
Page 258 TROUBLESHOOTING TIPS PROBLEM CAUSE/SOLUTION 1. Installed the alternator and connected the A self-energizing type alternator can lose its residual magne- cables (B+/B-(GND)) but the alternator has no tism and not work properly. Residual magnetism is the small output. What could be wrong? amount of magnetic field that remains in the alternator when there is no field current present.
Page 259 PROBLEM CAUSE/SOLUTION 4. The regulator has four different voltage settings The voltage regulator is equipped with a selectable voltage from 27.0V to 29.5V on the 28.0V systems. set point. This feature allows the choice of the regulated volt- Which is used? age output of the alternator according to the type of batteries in use on the truck.
Page 260 PROBLEM CAUSE/SOLUTION 5. What is an alternator field coil, and how can the coil be The alternator field coil acts as an electromagnet tested? when field current is applied. The stronger the mag- netic field, the higher the alternator output when the Refer to the Field Coil tests section for additional testing shaft is turned.
Page 261 PROBLEM CAUSE/SOLUTION 8. When the alternator voltage is measured at the alterna- When there is a difference in voltage measured tor (B+) terminal, it is considerably higher than alterna- between two places in the same circuit, the most tor voltage measured at the battery (B+) terminal. What likely cause is excessive resistance in that circuit.
Page 262 2. Radiator Removal The following instructions cover the removal of alter- nator (1, Figure 10-17) from a Komatsu engine. Radi- ator (2) has been removed from the truck in some pictures to clearly show the removal process. How- ever, the radiator does not need to be removed to remove the alternator.
Page 263 4. Remove ground strap (1, Figure 10-19) from 5. Remove eight lock nuts (1, Figure 10-21) from the alternator by removing cap screw (1, Figure the front cover of the belt guard assembly. 10-20). It is not necessary to completely remove 6.
Page 264 1. Alternator Bracket 2. Lock Nut Special Tools and Lubricants (Top Half) Table 10-9: REQUIRED LUBRICANTS AND SEALANTS For additional information on disassembling the alter- Komatsu Description nator, see the Alternator Disassembly procedure in Part # this chapter. XA3401 Grease...
Page 265 Epoxy Adhesive Elastoplastic Silicone Resin Master Bond, Inc. Dow Corning 1-2577 Low VOC RTV is a one-part 154 Hobart Street clear, RTV cure with mild heat acceleration possible. Hackensack, NJ 07601 USA It has a hard slick finish with abrasion resistance, sol- Phone: 201-343-8983 vent-borne with low VOC which is ozone-safe.
Page 266 Table 10-10: REQUIRED TOOLING XA3320 Field Coil Removal/Installation Tool XA3322 Stator Installation Tool Customer-supplied dealer manufactured support stand Three jaw gear puller (rotor removal, anti-drive end housing, and anti-drive end shaft bearing) Air impact wrench (pulley nut and fan nut) Air chisel with a rounded point hammer bit (to loosen rust from rotor, item 47) Torque wrench (inch pounds)
Page 267 NOTES D10003 07/06 Battery Charging Alternator D10-37...
Page 268 ALTERNATOR EXPLODED VIEW FIGURE 10-28. ALTERNATOR D10-38 Battery Charging Alternator D10003 07/06...
Page 269 1. Lock Nut 36. Harness, Wiring 2. Flat Washer 37. Regulator 3. Pulley (supplied with engine) 38. Screw, Hex 4. Bushing, Pulley 39. Washer, Stainless Steel Bellville 5. Ring, Spiral 40. Washer, Bellville 6. Screw, Pan 41. Lock Nut 7. Plate, Cover 42.
Page 270 Regulator Removal 1. Remove voltage regulator (37). a. Disconnect wiring harness (36) from voltage regulator (37). Wedges must be reinstalled and sealed in place b. Remove and save four screws (38) and four as described in Step ? to prevent damage to the Bellville washers (39) using an 8 mm socket.
Page 271 set point switch on the back side of the voltage 2. Remove fan (65) by removing nut (67) using an regulator. When installing a new voltage regula- air impact wrench and a 24 mm socket. Also, tor, set the selectable voltage set point switch to remove Bellville washer (66).
Page 272 Anti-Drive End Housing Removal 1. Scribe a single mark on side of shell (58) and drive end housing (20). Scribe a double mark on the side of shell (58) and anti-drive end housing (64). This will ensure the proper reassembly of the end housings.
Page 273 3. Remove and discard nine lock flange nuts (14) NOTE: Disassembly of the alternator can be made from anti-drive end housing (64) using a 9 mm easier by using a support stand, as shown. The socket. Support Stand section in this chapter provides dimensions to manufacture the stand.
Page 274 5. Remove and discard two O-rings (63) from 7. Remove and discard spiral ring (50) from carrier inside diameter of anti-drive end housing (64). ring (51). FIGURE 10-42. FIGURE 10-44. 63. O-Rings 64. Anti-Drive End 50. Spiral Ring 51. Carrier Ring Housing 6.
Page 275 NOTE: If necessary to loosen rust, use an air chisel with a rounded-point hammer bit to vibrate the area between screw holes on the rotor face. 4. Thread three screws (46) into the puller holes. Tighten the screws evenly to start removing The rotor retaining screws have been installed rotor (47) from rotor shaft (48).
Page 276 5. Remove the rotor from the rotor shaft. 2. Place the alternator in the support stand with the drive end facing up. FIGURE 10-50. FIGURE 10-52. Drive End Housing Removal 3. Remove cover plate (7) by removing six Torx screws (6) using a number T20 Torx bit. Ensure the single mark has been scribed between drive end housing (20) and shell (58).
Page 277 4. Remove six hex jam nuts (11, Figure 10-54) 5. Mark the location of the six phase leads for using an 11 mm socket. Remove the phase proper reassembly. Place a different identifica- leads from the terminals. If necessary, remove tion mark on both the housing and each phase flat washers (12, Figure 10-55) and insulators lead terminal.
Page 278 7. Remove the sealing compound from the face of 9. Carefully pull out and disconnect plug (30) from the drive end housing where the field coil leads receptacle (33) by releasing the lock and dis- enter the control unit connecting the gray plug assembly. FIGURE 10-58.
Page 279 11. Using a small flat-blade screwdriver, release the 13. Pull the field coil leads through the opening in female pin connectors from the plug assembly. the drive end housing. FIGURE 10-62. FIGURE 10-64. 12. Remove the two field coil leads from plug (30), 14.
Page 280 15. Remove pulley bushing (4). 16. Remove spiral ring (5) from pulley bushing (4) and discard. FIGURE 10-66. 4. Pulley Bushing 20. Drive End Housing FIGURE 10-68. 4. Bushing 5. Spiral Ring NOTE: Use a pair of expandable pliers and gently wiggle (move side-to-side) the pulley bushing out of 17.
Page 281 18. Press rotor shaft (48) out of front bearing (9). 20. Remove flat retainer ring (10) using heavy-duty internal snap ring pliers. Save the ring. FIGURE 10-70. FIGURE 10-72. 9. Front Bearing 48. Rotor Shaft 10. Flat Retainer Ring 9. Front Bearing 19.
Page 282 2. Remove one Torx screw (46) using a number T25 Torx bit. Scribe a mark on the face of the rotor at the center of the screw hole. This will be used to correctly position the rotor during assembly. Use a bearing driver with a slightly smaller diam- eter than the outer race of the bearing.
Page 283 Field Coil Removal 4. Reposition the alternator in the support stand with the drive end facing up. DO NOT damage or bend studs (61). 1. Position the alternator in the support stand with the anti-drive end facing up. 2. Permanently mark the letters ADE on the sur- face of field coil (60) in the location of the miss- ing screw.
Page 284 7. Place XA3320 field coil removal/installation tool on top of the field coil. DO NOT damage the field coil leads during the removal process. NOTE: If a new field coil will be installed, mark the letters (in the same location and orientation) from Steps 2 and 5 on the new replacement field coil.
Page 285 Drive End and/or Anti-Drive End Stator Removal 4. Permanently scribe or etch a single mark aligned with the center of two stud holes, across the top surface of anti-drive end stator (59) and end of shell (58). Repeat at an adjacent hole. Remove and replace one faulty stator at a time.
Page 286 5. Remove the shell assembly from the support 8. Position the shell in the support stand with the stand. Remove hex head nuts (54) from studs faulty stator in a downward position. Place sta- (61) using a deep well 6 mm socket. Discard tor installation/removal tool XA3320 on top of nuts (54).
Page 287 CLEANING AND INSPECTION 10. Carefully pull the three anti-drive end stator phase leads through the spaces between the 1. Ensure all parts being reused are thoroughly stator windings. clean. 2. Ensure all parts being reused are in good condi- tion. Replace any damaged parts. ALTERNATOR ASSEMBLY Before starting the installation procedure, ensure all the parts are available and in good condition.
Page 288 4. Insert six alignment studs through the holes in NOTE: If the drive end stator will not be replaced, anti-drive end stator (59) aligning them with the route the phase leads from the replacement anti- holes in drive end stator (56). drive end stator through the corresponding spaces (marked in Step 7a of the Disassembly procedure, page 55) between the drive end stator windings.
Page 289 8. If the drive end stator needs to be replaced, fol- low the steps in the next section. If the drive end stator does not need replacement, go to the Field Coil Installation section in this manual. Drive End Stator Installation Ensure the shell is supported in a hydraulic press so the alignment studs are not damaged by This procedure assumes the anti-drive end stator is...
Page 290 b. Alternative method: Remove the insulation 4. Place the stator in the opening of the shell. Pre- sleeves from the three anti-drive end phase cisely align the scribed mark. It is critical that leads. DO NOT damage the insulation this scribed mark be carefully aligned. If the sleeves during removal.
Page 291 6. Place the shell with the stator in a hydraulic 8. Remove the shell and stator assembly from the press. Place stator installation tool XA3322 on press. Remove the installation tool. Remove the top of the stator. Position the studs in the open- six alignment studs.
Page 292 10. Install hex head nuts (54) onto the studs. Use a 2. Align the letters ADE on the field coil with the suitable thread lock compound such as Loctite non-tabbed portion of the stator, and route the 222. Tighten the nuts to 3 N·m (30 in. lb) in an two field coil leads through the corresponding alternating pattern.
Page 293 3. Carefully push the field coil downward through 5. Engage the recessed areas of the tool with the stator tabs (59). The clearance between the field coil bobbin ears. Rotate the tool clockwise field coil and stator is minimal and will require approximately five degrees to engage the field care during the installation process.
Page 294 DO NOT install a screw in the marked hole DO NOT install a screw in the marked hole because there is no corresponding stator tab. If because there is no corresponding stator tab. If installed, the screw will fall into the stator cavity, installed, the screw will fall into the stator cavity, damaging internal parts during operation.
Page 295 2. Place drive end housing (20) and front bearing 4. Lubricate the spiral ring with Komatsu grease (9) in a hydraulic press. Press the bearing into XA3401. Wind new spiral ring (5) into the the bore until completely seated against the flat groove around pulley bushing (44).
Page 296 Drive End Rotor Installation Rotor and Rotor Shaft Installation 1. If removed, install drive end rotor (47) onto shaft 1. Press rotor and rotor shaft assembly (47, 48) assembly (48). into drive end housing (20). a. Place the rotor and rotor shaft assembly into a hydraulic press with the rotor shaft fully supported.
Page 297 Drive End Housing Installation 3. As the drive end housing is installed, guide the two field coil leads and the six stator phase 1. Place shell assembly (58) into the support leads through the proper openings in the drive stand with the drive end facing up. end housing.
Page 298 4. Install nine new lock flange nuts (14) onto studs 6. Place the stator phase leads onto the stator (61). Tighten the nuts to 5 N·m (45 in. lb) using phase lead studs and install new hex jam nuts an alternating pattern. (11).
Page 299 7. Lubricate the spiral ring with Komatsu grease 9. Guide the two field coil leads through the open- XA3401. Wind new spiral ring (5) into the ing in the drive end housing and into the control groove around pulley bushing (4).
Page 300 10. Install the orange wire seal over the field coil 11. Connect plug assembly (30) with receptacle leads. Install the two terminal sockets into plug assembly (33). assembly (30). Install orange wedge (32) to lock the sockets into the plug. FIGURE 10-129.
Page 301 13. Install cover plate (7). Apply thread lock com- Anti-Drive End Rotor Installation pound (Loctite) and install six Torx screws (6) 1. Reposition the alternator in the support stand using a T20 Torx bit. Tighten the screws to 3 N·m with the anti-drive end facing up.
Page 302 Anti-Drive End Housing Installation install five Torx screws (46) using a T25 Torx bit. 1. Lubricate the spiral ring with Komatsu grease DO NOT install a screw in the scribed hole at XA3401. Wind new spiral ring (50) into the this time.
Page 303 3. Compress spiral ring (50) and install carrier ring 5. Apply thread lock compound (Loctite 222) and assembly (51) into the anti-drive end housing, install nine new lock flange nuts (14). Tighten to (towards the inside of the alternator). This part 5 N·m (45 in.
Page 304 Pressing on any other surface will result in bearing damage. 7. Rotate the shaft to verify the bearing moves freely. 8. Lubricate the spiral ring with Komatsu grease XA3401. Wind new spiral ring (50) into the groove around fan (65).
Page 305 11. Remove the alternator from the support stand. NOTE: The setting of this switch can depend on the Install woodruff key (49) in the rotor shaft. type of battery being used. Refer to Battery in this Install pulley (3) with flat washer (2) and nut (1). chapter for additional information.
Page 306 THERMAL SWITCH 3. Remove the plastic tie strap securing the wires together. Removal 1. Disconnect wiring harness plug (36) from volt- age regulator (37). FIGURE 10-152. FIGURE 10-150. 4. Remove all the sealant from around thermal switch (22). 36. Wiring Harness Plug 37.
Page 307 5. Remove hex head bolt (23) using a 13 mm 7. Remove thermal switch (22). socket. Also, remove Bellville washer (24) and a. Reposition the two insulation sleeves to flat washer (25). expose the wiring connections. b. Remove the heat shrink insulation from both wiring connections.
Page 308 SUPPORT STAND Installation 1. Place the appropriate diameter heat shrink Disassembly of the alternator can be made easier by insulation onto the thermal switch wires. using a support stand, as shown. This drawing pro- vides the dimensions to manufacture the stand. 2.
Page 309 SECTION D11 VHMS COMPONENTS INDEX VHMS BASIC FEATURES 3 Gather Data ............. . D11-3 Convert and Record Data .
Page 310 NOTES: D11-2 VHMS COMPONENTS D11005...
Page 311 VHMS COMPONENTS VHMS BASIC FEATURES Convert and Record Data The center of the VHMS system is the VHMS control- VHMS controller (2, Figure 11-1) processes data ler which gathers data about the operation of the received from external controllers and stores the fol- truck from sensors and other controllers installed on lowing data in internal memory: the truck.
Page 312 • Download to a laptop PC running the VHMS PC. This data is to be sent to Komatsu via the FTP Technical Analysis Toolbox software program which is a part of the VHMS Technical Anal- ysis Tool Box program.
Page 313 Turning the VHMS System ON The VHMS controller is turned on by the truck key switch (circuit 712). Immediately after receiving input from the key switch signal, the VHMS controller begins its power-up initialization sequence. This sequence takes about three seconds, during which time red LED digits (4, Figure 11-1) on the top of the VHMS controller unit will display a circular sequence of flashing LED segments.
Page 314 Turning the VHMS System OFF Downloading from the VHMS Controller The VHMS controller is connected directly to the Downloading data requires a laptop PC running Win- truck batteries, but will remain in normal operation dows 95/98/2000/ME/XP operating system, the only if the truck key switch input (circuit 712) is on. VHMS Technical Analysis Toolbox software, and a When the VHMS controller senses that the truck key serial cable to connect the laptop PC to the VHMS...
Page 315 Table 3: File Types of Download Data File Name Data Type Description cyc_int0 Cycle Interval Changes in engine speed csvdata_3f.csv Temporary Brake Load Map Fault0.csv Fault History Records all faults index00.csv Index Lists all common data files loadm1.csv Temporary Load Map mcn_his0.csv Machine History Key On, Key Off...
Page 316 Snapshots Manual Snapshots A snapshot is a time history of real-time data that is A manual snapshot is taken by pressing the data recorded before and after the instant that a fault code store button (1, Figure 11-5), located at the rear of occurs.
Page 317 Table 4: Snapshot Data Data Item Data Source Model Note Engine Coolant Temperature Cummins QUANTUM Controller Engine Oil Pressure Cummins QUANTUM Controller Accelerator Position% Cummins QUANTUM Controller Engine Speed Cummins QUANTUM Controller Exhaust Gas Temperature (Left Front) Cummins CENSE Controller Exhaust Gas Temperature (Left Rear) Cummins CENSE Controller Exhaust Gas Temperature (Right Front)
Page 318 Trends The VHMS controller maintains an engine speed vs. fuel rate histogram called the Engine Load Map, and The VHMS controller develops trends by monitoring a brake pressure vs. speed histogram. real-time data, and reducing the data into 20 hour statistical values.
Page 319 Haul Cycle Data VHMS controller maintains a record of the payload summary data from the past 100 daily transmissions The VHMS controller downloads haul cycle data from to OrbComm. Payload Meter III one time every 24 hours, at a time specified by the VHMS Setting Tool software.
Page 320 VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code #A018 RR Flat Cylinder Warning PLM III 830E-AC #A019 LR Flat Cylinder Warning PLM III 830E-AC #A101 Pump Filter Switches 830E-AC #A107 Propel System Caution 830E-AC #A108...
Page 321 Table 6: Alarm and Snapshot Triggers (Continued) VHMS VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code C00143 Low Oil Pressure Engine C00151 High Coolant Temperature Engine C00155 High IMT LBF Engine C00158 High IMT LBR Engine C00162 High IMT RBF...
Page 322 VHMS DIAGNOSTIC FEATURES VHMS CONTROLLER The VHMS system provides several basic data items The VHMS controller collects and stores signals from that are useful for troubleshooting failures in the sensors and data from other controllers. It also gives VHMS system itself. commands for transmitting the accumulated data through the communications system.
Page 323 [OK] and [Yes] buttons to confirm. Komatsu North America as shown on the form. Then select the [Close] button. 8. Fill out a “VHMS Initialization” form and send it to Komatsu as instructed on the form.
Page 324 Komatsu must have this information to maintain accurate data. 5. It may take up to two weeks for Komatsu to acti- vate the new OrbComm controller. During this time, a manual download of data must be taken one time each week using a laptop PC.
Page 325 INTERFACE MODULE 6. Turn the key switch OFF and wait one minute. The interface module collects data from various sen- sors and sends this information to the VHMS control- 7. Turn the key switch ON, but do not start the ler through the main wiring harness.
Page 326 SENSORS Pressure Sensors Four pressure sensors (Figure 11-10) have been Temperature Sensors added to the truck to monitor various hydraulic cir- Temperature sensors (Figure 11-9) monitor the cuits. The four circuits are: ambient air temperature and the hydraulic oil temper- •...
Page 327 SECTION D12 VHMS SOFTWARE INDEX VHMS SOFTWARE ............. . D12-3 NECESSARY SOFTWARE .
Page 328 1. VHMS CONTROLLER SETUP PROCEDURE ........D12-6 VHMS Setting Tool software program .
Page 329 Application code for interface module Komatsu Distributor Application Code 1.4.7.39 Payload Meter III Data Manager Komatsu Distributor EJ0575-5 PLM III PLM III Controller Software to work with VHMS Komatsu Distributor NECESSARY TOOLS Table 2: VHMS Tools Part Number Name Description Source Laptop PC...
Page 330 (such as Software C:\temp). VHMS CONTROLLER •830E-AC - File name is EM2126-0.exe • VHMS Tool Box 2. Double click on the correct application code file so it will extract the file. Chose a folder on a •...
Page 331 INTERFACE MODULE REALTIME DATA VHMS CONTROLLER MONITOR SOFTWARE PROGRAM VHMS TOOL BOX The Interface Module Realtime Data Monitor Soft- ware is used to display the data going into and out of Installation the interface module. The program is installed onto a 1.
Page 332 VHMS INITIALIZATION PROCEDURE 1. VHMS CONTROLLER SETUP PROCEDURE When a new VHMS equipped machine is being assembled, there are several procedures to perform VHMS Setting Tool software program in order to initialize the VHMS system. Following the 1. Start the VHMS Setting Tool software program. procedures will ensure a smooth initialization pro- There will be three choices to choose from.
Page 333 VHMS Setting Function Machine Information Setting(2) 3. Select Set up & All clear if initializing a machine, 5. Verify that the Machine Information Settings are then click [Next]. correct. If not, enter the correct settings. Then click [Next]. Machine Information Setting(1) 4.
Page 334 GCC Setting 9. Click [YES]. 7. Choose the correct GCC code. The GCC code tells machines equipped with Orbcomm which satellite ground station to use. Then click [Next]. 10. Click [OK]. 11. Click [OK]. The VHMS Setting Tool program will close.
Page 335 On an 830E-AC truck, perform a horsepower utes. check using a laptop PC connected to the NOTE: On a 830E-AC drive truck, a laptop PC GE drive system. should also be connected to the GE drive system to 4. The white LED will begin flashing slowly after...
Page 336 3. VHMS DOWNLOAD PROCEDURE 16. Select the [Machine History] option from the list on the left side of the screen. NOTE: Always verify a full download has been taken 17. Verify that the key ON/OFF and engine ON/OFF before disconnecting the laptop PC from the records are recorded correctly.
Page 337 If someone provides VHMS download files through User ID and Password. e-mail or on a disk, the same folder organization User ID = komatsu must be created in order to view them in VHMS Password = vhms Technical Analysis Tool Box.
Page 338 “.K”. forms found in this section. Send the initialization P_830E_-_A30761_1105208857.K form to Komatsu. Initialization is now complete. 7. After selecting the correct file to send, click the [Send (FTP)] button.
Page 339 WHEN REPLACING A VHMS 3. Click the [Save] button. CONTROLLER Refer to VHMS Components, VHMS controller removal and installation instructions (elsewhere in this section) for replacing a VHMS controller. Follow the steps below when using the VHMS Setting Tool software to save the data and settings so they can be transferred from the old controller to the new control- ler.
Page 340 6. Select the [Use previous setting after replace- 8. If the correct data is not showing, click the ment of VHMS controller] function. [Select File] button and choose the correct data. Then click the [Next] button. 7. Verify that the data showing is the data to be 9.
Page 341 10. Click the [OK] button. To Set: Date & Time; Satellite; Payload Meter • Date & Time • Satellite • Payload Meter 1. Select the [VHMS Setting] function, then click the [Next] button. 11. Click the [OK] button. The Setting Tool Program will close.
Page 342 3. After selecting one of the following choices, 5. Satellite: Select the correct country location click the [Next] button. from the drop-down menu, then click the [Apply] button to change the setting. • [Date & Time] • [Satellite] • Payload Meter 6.
Page 343 Review Setting Information 1. Select the [Review setting information] function and then click the [Next] button. 3. Click the [Yes] button to close the Setting Tool Program. 2. Review the settings for accuracy. If something is not correct, click the [Back] button, select the appropriate category and reset the information to the correct settings.
Page 344 NOTES D12-18 VHMS SOFTWARE D12004...
Page 345 SECTION D13 VHMS CHECKOUT AND TROUBLESHOOTING INDEX INTERFACE MODULE AND VHMS CHECKOUT & TROUBLESHOOTING ....D13-3 GENERAL ..............D13-3 Structure and Purpose .
Page 346 NOTES D13-2 VHMS CHECK-OUT & TROUBLESHOOTING D13004...
Page 347 INTERFACE MODULE AND VHMS CHECKOUT & TROUBLESHOOTING GENERAL The center of the Vehicle Health Monitoring System The interface module should already have the appli- (VHMS) is the VHMS controller which gathers data cation code installed. If not, refer to the VHMS Soft- about the operation of the truck from sensors and ware procedures for “Installing Application Code Into other controllers installed on the truck.
Page 348 INTERFACE MODULE CHECKOUT Interface Module The interface module (1, Figure 13-2) collects data from various sensors and sends this information to the VHMS controller through the main wiring har- ness. It also controls some truck functions. If a new truck with VHMS is being assembled, or a new VHMS system has just been installed, refer to the VHMS Software instructions regarding the VHMS Initialization Procedure.
Page 349 Preliminary 7. Check for fault codes associated with the inter- face module. 1. Turn the key switch to the OFF position to stop the engine. a. Perform a VHMS download with the VHMS Technical Analysis Toolbox program. Refer 2. Turn the key switch to the ON position, but DO to VHMS Download for detailed instructions NOT start the engine.
Page 350 Check Digital Inputs To The Interface Module 4. Propel System Temp Caution - (IM3-A) short wire 34TW to ground at TB26-B momentarily 1. Hydraulic Tank Level (IM2-K) - short wire 34LL and confirm state change (one to zero). to ground at TB35-N momentarily and confirm 5.
Page 351 7. Pump Filter Switches (IM2-Y) - short wire 39L to 10. Reduced Propel System (IM3-B) - short wire ground at TB44-N momentarily and confirm 72LP to ground at TB25-W momentarily and state change (one to zero). confirm state change (one to zero). 8.
Page 352 12. Park Brake Request (IM3-V) - Place shifter into Check Analog Inputs To The Interface Module park position and confirm state change (zero to NOTE: Instead of using a resister in place of a one). sensor for verifying pressure readings, a calibrated 13.
Page 353 Check CAN RPC & J1939 Interfaces To The IM 3. With circuit 52B at TB35-L still shorted to 24 volts, confirm that the IM Warning lamp ener- gizes. 1. CAN/J1939 - (IM1-q,r,s): confirm fault A184, 4. With circuit 52B at TB35-L still shorted to 24 J1939 Not Connected, is not active.
Page 354 VHMS CONTROLLER CHECKOUT VHMS Controller The VHMS controller (1, Figure 13-6) collects and stores signals from sensors and data from other con- trollers. It also gives commands for transmitting the accumulated data through the communications sys- tem. The controller operates on 20VDC - 30VDC. Necessary Equipment: •...
Page 355 The interface module must be fully functional before 9. Select the [Review setting information] function performing the this checkout procedure. The VHMS and then click the [Next] button. controller must be initialized and fully functional before performing this checkout procedure. Preliminary 1.
Page 356 6. At the prompt, >, type "ver". Something similar changed, a new VHMS Initialization Form must to the following will be displayed: be filled out and submitted to Komatsu America >ver Service Systems Support Team. VHMS OS Ver 1.6.5.1 Mar 01 2004 16:37:25 •VHMS controller replaced...
Page 357 7. At the prompt type "dispvhmsinf". Information 8. The VHMS controller also has two red LED similar to the following will be displayed: lights (10 and 11, Figure 13-6). Verify the con- nection status and repair any problems. Light (10) PLM III communication >dispvhmsinf •...
Page 358 The VHMS system basically consists of five commu- data from the VHMS controller and sends this data nications networks connected to the VHMS and Orb- through the antenna to the Komatsu computer cen- Comm modem controllers. Figure 13-1 shows the ter.
Page 359 FAULT CODES Effective troubleshooting of RF communications sys- tems can be complex and cannot always be reduced Fault History to a simple check of electrical resistance. However, a few basic troubleshooting procedures may be helpful The fault history recorded in the VHMS controller can in identifying common problems.
Page 360 VHMS LED Display Fault Codes When no communication errors are occurring, the The VHMS controller also indicates some faults on VHMS LED digits count from 00 - 99 continuously at the two red LED digits on the top of the controller. a rate of ten numbers per second.
Page 361 Chassis Fault Codes Fault codes generated from the truck chassis, PLM III or GE are shown in Table 3. Table 3: Chassis Fault Codes VHMS VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code LF Pressure Sensor Signal High PLMIII LF Pressure Sensor Signal Low PLMIII...
Page 362 Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code #A101 Hydraulic Oil Filter Differential 830E-AC Pressure High #A103 Hydraulic Tank Temp - Sensor Low 830E-AC #A104 Hydraulic Tank Temp - Sensor High 830E-AC #A105 Fuel Level Sensor Low 830E-AC...
Page 363 VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code #A198 Hoist Pressure 1 Sensor High 830E-AC #A199 Hoist Pressure 2 Sensor High 830E-AC #A200 Steering Pressure Sensor High 830E-AC #A201 Brake Pressure Sensor High 830E-AC #A202...
Page 364 Engine Fault Codes Table 4: Engine Fault Codes VHMS VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code C112 Timing Fueling Flow Mismatch Engine C113 Timing Actuator Circuit Shorted Engine C115 Speed Signal Lost Engine C116 Timing Rail Pressure Ckt Failed High Engine C117 Timing Rail Pressure Ckt Failed Low...
Page 365 Table 4: Engine Fault Codes (continued) VHMS VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code C162 High IMT RBF Engine C163 RBR IMT Ckt Failed High Engine C164 RBR IMT Ckt Failed Low Engine C165 High IMT RBR Engine C212...
Page 366 Table 4: Engine Fault Codes (continued) VHMS VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code C384 Ether Solenoid Ckt Failed Engine C422 Coolant Level Signal Invalid Engine C423 Timing Press Incorrect Engine C426 J1939 Broadcast Data Missing Engine C427 J1939 Datalink Can Not Transmit...
Page 367 Table 4: Engine Fault Codes (continued) VHMS VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code C633 Low Power #3 RB Engine C634 Low Power #4 RB Engine C635 Low Power #5 RB Engine C636 Low Power #6 RB Engine C637 Low Power #7 RB...
Page 368 Table 4: Engine Fault Codes (continued) VHMS VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code C676 Exh Temp Ckt Failed Low #6 LB Engine C677 Exh Temp Ckt Failed Low #7 LB Engine C678 Exh Temp Ckt Failed Low #8 LB Engine C694 LBR Turbo Comp Inlet Temp Sensor...
Page 369 Table 4: Engine Fault Codes (continued) VHMS VHMS Fault Description Source Sent via Snapshot Model Notes Fault OrbComm Trigger Code C2154 Post Oil Filter Press Ckt Failed High Engine C2155 Post Oil Filter Press Ckt Failed Low Engine C2157 Rapid Rise in LBR IMT Engine C2158 Rapid Rise in RBF IMT...
Page 370 FAULT TREE ANALYSIS Unable to connect to VHMS from laptop PC D13-26 VHMS CHECK-OUT & TROUBLESHOOTING D13004...
Page 371 Flashing Error Code N4-23 (PLM III Communications Fault) D13004 VHMS CHECK-OUT & TROUBLESHOOTING D13-27...
Page 372 Flashing Error Code N4-22 (Engine Communications Fault) D13-28 VHMS CHECK-OUT & TROUBLESHOOTING D13004...
Page 373 No Data Received By WebCARE D13004 VHMS CHECK-OUT & TROUBLESHOOTING D13-29...
Page 374 Coaxial Cable Troubleshooting D13-30 VHMS CHECK-OUT & TROUBLESHOOTING D13004...
Page 375 SECTION D14 VHMS FORMS INDEX VHMS FORMS ..............D14-3 VHMS INITIALIZATION CHECK LIST .
Page 376 NOTES D14-2 VHMS - Forms 01/06 D14003...
Page 377: Vhms Forms
VHMS FORMS The preferred method to submit this form is in 2. Using a serial cable, connect a laptop PC to the electronic format. This check list and initialization VHMS controller. form are available in PDF format, where the 3. Turn the key switch ON, check operation of the information can be typed into the form.
Page 378: Vhms Data Download
ON/ OFF is stored in machine history file. d. Set Start Time to “0”. 3. E-mail the downloaded data files to Komatsu e. Set Interval to “1”. America Service Systems Support Team at f.
Page 379 Machine Information • Enter machine information. All fields are required. • VHMS and Orbcomm controller part numbers and serial numbers can be found on a sticker on each controller. Verify that this matches the information displayed in the VHMS Setting Tool and download.
Page 380: Vhms Initialization Check List
VHMS INITIALIZATION CHECK LIST (Page 1 of 2) Date of set-up (MM/DD/YY) Distributor and FOR: 730E, 830E, 930E & 960E DUMP TRUCKS Branch Person performing initialization Item To be checked when Check Item Results 1. Key switch OFF Machine Model Number Machine Serial Number Service Meter Reading Engine Serial Number...
Page 381 Manual snapshot recorded and no data missing? Manual snapshot data recorded in fault history, key switch ON/OFF and engine on/off records are saved in machine history file? 3. Send download data to Komatsu Send download data to KAC Service Systems Support at ServicePrograms@komatsuNA.com...
Page 382: Vhms Initialization Form
VHMS INITIALIZATION FORM NOTE: This form is available in electronic “fill-in” format, which is preferred. If an electronic form is needed, send request to ServicePrograms@KomatsuNA.com. After filling out the form, save the file using the Model Type, Serial Number and “VHMS Initialization” in the file name. (Example: 930E-3SE-A30300-VHMS Initialization.pdf), 1.
Page 383 SECTION E ELECTRIC PROPULSION SYSTEM INDEX ELECTRIC PROPULSION SYSTEM COMPONENTS ........E2-1 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE .
Page 384 BEFORE WELDING ON THE TRUCK; Disconnect all electrical harnesses and the ground wire from the Engine Control System (ECS - MTU engine). If equipped with DDEC or Komatsu engine, disconnect ECM harnesses. In the PSC and TCI enclosures, pull cards forward far enough to disconnect the card connector from the backplane connector.
Page 385 SECTION E2 ELECTRICAL PROPULSION SYSTEM COMPONENTS INDEX ELECTRICAL PROPULSION SYSTEM COMPONENTS ........E2-3 GENERAL SYSTEM DESCRIPTION .
Page 386 EVENT DETECTION AND PROCESSING ......... . E2-32 Power-On Tests .
Page 387 ELECTRICAL PROPULSION SYSTEM COMPONENTS The following information provides a brief description The alternator field is supplied from a tertiary winding of system operation and major components of the AC on the alternator and is controlled by a silicon propulsion system. Refer to the appropriate GE controlled rectifier (SCR) bridge.
Page 388 FIGURE 2-1. PROPULSION SYSTEM DIAGRAM E2-4 Electrical Propulsion System Components 10/06 E02020...
Page 389 SYSTEM COMPONENTS The ICP (Integrated Control Panel) consists of three The PSC contains the following internal, removable major components: the PSC (Propulsion System printed circuit boards and two fiber optic boards: Controller), the TCI (Truck Control Interface) and the System Card: Provides serial...
Page 390 Truck Control Interface (TCI) The TCI contains the following internal, removable printed circuit boards: The TCI is the main interface between the truck systems/devices and service personnel. This panel is CPU Card: Provides high speed communications to PSC and RS232 serial communication with the used in conjunction with the DID panel.
Page 391 Diagnostic Information Display (DID) Panel DID Panel Event Codes The DID panel (Figure 2-2) is located in the cab The tables on the following pages list the possible behind the operator’s seat. The display provides event codes which may be displayed on the DID service personnel with a means of communicating panel when accessed.
Page 392 Table 2: DID PANEL FAULT CODES (Codes Received from PSC) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION NO FAULT None Displayed when all faults have been reset GROUND FAULT No power A ground fault has been detected: For voltage < 1000 V, detection threshold is 166 mA For voltage >= 1000 V, detection threshold ramps from 166 mA at 1000 V down to approximately 70 mA at approximately 1500 V.
Page 393 Table 2: DID PANEL FAULT CODES (Codes Received from PSC) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION ANALOG SENSOR FAULT alt field amps link amps load box amps 3 phase alt volts alt field volts PSC link volts inv1 link volts Speed limit Incorrect input from a sensor inv2 link volts...
Page 394 Table 2: DID PANEL FAULT CODES (Codes Received from PSC) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION TCI COMM. FAULT PSC received no serial data from TCI over period of time. Message missing Bad tick Bad CRC No propel Overflow Bad start Bad stop...
Page 395 Table 2: DID PANEL FAULT CODES (Codes Received from PSC) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION GY19 GRID BLOWER FAILURE blower 1 stall blower 2 stall No power A grid blower has failed. blower 1 open blower 2 open blower 1 &...
Page 396 Table 2: DID PANEL FAULT CODES (Codes Received from PSC) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION FRONT WHEEL TACHS SYS Event INVERTER SW VERSION Incorrect version of Inverter Software is installed. Inverter # 1 SYS Event Inverter # 2 MOTOR OVERSPEED SYS Event Truck is over the motor overspeed limit.
Page 397 Table 2: DID PANEL FAULT CODES (Codes Received from PSC) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION FB173 CARD FB173 card failure speed FPGA DL speed FPGA run ALT FPGA DL Microcontroller slow task No power med task fast task FD task Alternator 3 phase volts bad alt FPGA timeout...
Page 398 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 100/200 INVERTER CPU CARD (FB172) pat fail out 100 Pattern had bad A, B, C output 100%. no extvi TIC Extrapolation interrupt not running no vector TIC Vector interrupt not running...
Page 399 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 102/202 INV I/O CARD (FB172) gnd not ok Logic ground not OK no IO card Could not access I/O card eoc not working A/D conversion did not work.
Page 400 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 103/203 INV I/O CARD (NR) DB chopV too hi DB chopper voltage too positive VA VCO hi High frequency on VCO VA channel VB VCO hi High frequency on VCO VB channel VC VCO hi...
Page 401 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 113/213 INVERTER, GENERAL Aup cur hi Phase A current out too high Adn cur hi Phase A current in too high Bup cur hi Phase B current out too high Bdn cur hi...
Page 402 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 113/213 INVERTER, GENERAL B volt hi off Phase B voltage high with all IGBTs off B volt lo off Phase B voltage high with all IGBTs off C volt hi off Phase C voltage high with all IGBTs off...
Page 403 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 119/219 INVERTER, PHASE A- alarm AN Phase A negative IGBT did not turn off. Adn fb not off Phase A down feedback is not off. phase A modl neg Phase A negative module failed.
Page 404 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 127/227 INVERTER, PHASE B+ Bup temp short Phase B up thermistor short Bup temp open Phase B up thermistor open None Bup temp warm Phase B up thermistor warm...
Page 405 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 135/235 INVERTER, PHASE C+/C- alarm CP Phase C positive IGBT did not turn off. Cup fb not off Phase C up feedback is not off. phase C modl pos Phase C positive module failed.
Page 406 Table 3: DID PANEL FAULT CODES (Codes Received from Inverter 1 & 2) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION 146/246 INVERTER, TACH 2 (NR) None tach2 one channel Tach 2 single channel operation 148/248 INVERTER, CHOPPER 1 (NR) chop1 fb not off Chopper 1 feedback is not off.
Page 407 Table 4: DID PANEL FAULT CODES (Codes Received from TCI) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION TCI FB144 CPU CARD 10ms task failed to init 20ms task failed to init 50ms task failed to init TCI CPU card problem 100ms task failed to init 200ms task failed to init No propel...
Page 408 Table 4: DID PANEL FAULT CODES (Codes Received from TCI) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION ENGINE START REQUEST DENIED engine warn while cranking Engine warning occurs after engine crank command is SYS Event given. engine kill while cranking Engine kill input occurs while engine crank command is active.
Page 409 Table 4: DID PANEL FAULT CODES (Codes Received from TCI) EVENT EVENT EVENT DETECTION NUMBER DESCRIPTION RESTRICTION INFORMATION BBRAM CORRUPTED SYS Event Battery backed RAM has failed. TRUCK OVERLOADED - RESTRICTIVE NO PROPEL The over-payload signal is on, operation restricted. TRUCK OVERLOADED - NON-RESTRICTIVE SYS Event The over-payload signal is on, propulsion allowed.
Page 410 PSC SOFTWARE FUNCTIONS Test State: The purpose of this state is to provide an environment verification system The operation of the AC drive system is regulated by functionality. The test state will support a variety of a software program which resides in the propulsion activities, including: system control panel's memory.
Page 411 Transitions between states under normal operational Transition to Rest State: This transition will occur conditions (no failures, etc.) are described as follows: automatically from the Test or Ready state if a request for Rest state is received from the TCI and all of the following conditions are true: Transition to Startup/Shutdown State •...
Page 412 Transition from Ready State to Retard State: This Transition from Propel State to Retard State: This transition will occur if truck speed is such that retard transition will occur if at least one of the following is allowed and at least one of the following conditions conditions exists: exists: •...
Page 413 DC Link State De-Powering the DC Link: The PSC software will attempt to de-power the DC link (command the Power is provided to the inverters and motors via the system configuration defined below) if the system is DC link. The DC link has two associated states: in Test or Ready state and any of the following powered and unpowered.
Page 414 ALTERNATOR FIELD CONTROL Engine Control This software function generates the engine speed The alternator is controlled by controlling the command. The engine electronic fuel control is alternator field reference sent to the AFSE panel. responsible for maintaining that speed. The desired alternator output voltage is dependent The desired engine speed is determined according to on the system state.
Page 415 Self-Load • Jerk Limit The torque command will be slew-rate limited to During self-load, the alternator provides power to the prevent jerking motion. resistor grids. The rectifying diodes will be forward biased, and DC link voltage will be controlled by the •...
Page 416 Wheel Slide Control Power-On Tests The inverters prevent wheel slide by limiting torque to Three power-on tests are executed once every time maintain wheel speeds above preset limits. These power is applied to the PSC. They are as follows: preset limits are a function of truck speed and the •...
Page 417 EVENT RESTRICTIONS • DC Link Capacitance Test - This test will run once every 24 hours when conditions allow, normally The PSC software will not override an event after a VI-test during the normal power-up restriction as long as the “limp home” mode is not sequence.
Page 418 Event History Buffer All logic control variables are saved in battery backed RAM, in case a fault occurs and battery power is Event history buffer is defined as a collection of event cycled before the data pack is filled with data (the history records.
Page 419 SERIAL DATA COMMUNICATIONS TCI: 1. With the PTU serial cable attached to the TCI The PSC system CPU card uses serial data busses port, type c:\ACNMENU and press {enter}. to communicate with the TCI, the PTU, and the two inverter CPU cards. 2.
Page 420 ABNORMAL CONDITIONS/OVERRIDING Inverter Communications Processing FUNCTIONS This software function performs the processing necessary for the PSC system CPU card to Software functions given up to this point have communicate with both inverter CPU cards. The assumed that the truck is operating under typical communication is through a high-speed serial link circumstances.
Page 421 Limp Home Mode The purpose of limp home mode is to address the The PSC will exit limp home mode if either of the situation where the truck has suffered a failure and is following conditions occur: not able to continue normal operation but is still •...
Page 422 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS The Table 5 lists component abbreviations that are used in schematics and system description information. Refer to Figures 2-3 through 2-6 for the location of the components. A short description of the component's primary function is also listed.
Page 423 Table 5: PROPULSION SYSTEM COMPONENTS DESCRIPTION FIG. COMPONENT FUNCTION CM11A - 12C Current Sensing Modules, Phase Detects amount of current flow through the A, B and C phases of Traction Motor 1. 1A, 1B and 1C CM21A - 22C Current Sensing Modules, Phase Detects amount of current flow through the A, B and C phases of Traction Motor 2.
Page 424 Table 5: PROPULSION SYSTEM COMPONENTS DESCRIPTION FIG. COMPONENT FUNCTION Integrated Control Panel The ICP is the main controller for the AC drive system. The ICP is composed of the PSC, TCI and inverter cards. Inverter 1 Central Processing Generates Phase Module turn-on/turn-off commands for the Inverter 1.
Page 425 Table 5: PROPULSION SYSTEM COMPONENTS DESCRIPTION FIG. COMPONENT FUNCTION Battery Boost Resistor Limits surge current in the Alternator field circuit when GFR contacts first close. SS1, 2 Traction Motor Speed Sensors Each speed sensor provides two output speed signals, proportional to the Traction Motor's rotor shaft speed. SYS CPU Card System Central Processing Unit Provides control of propulsion and dynamic retarding...
Page 426 FIGURE 2-3. CONTROL CABINET COMPONENTS - HIGH VOLTAGE INVERTER AREA E2-42 Electrical Propulsion System Components 10/06 E02020...
Page 427 FIGURE 2-4. CONTROL CABINET COMPONENTS - LOW VOLTAGE CONTROL AREA E02020 10/06 Electrical Propulsion System Components E2-43...
Page 428 FIGURE 2-5. CONTROL CABINET COMPONENTS - CONTACTOR COMPARTMENT E2-44 Electrical Propulsion System Components 10/06 E02020...
Page 429 FIGURE 2-6. CONTROL CABINET COMPONENTS - REAR CABINET VIEW E02020 10/06 Electrical Propulsion System Components E2-45...
Page 430 ELECTRONIC ACCELERATOR AND Disassembly RETARD PEDALS 1. Remove the screws for cable clamps (1, Figure 2-11). The clamps can remain attached to wiring The accelerator pedal provides a signal to the Truck harness (2). Control Interface (TCI) when the operator requests power.
Page 431 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE ......E3-3 AC DRIVE SYSTEM MAINTENANCE .
Page 432 PSC ..............E3-25 TCI.
Page 433 System (ECS) harnesses and ground wire handhold when the engine is running. (MTU engine). If equipped with DDEC or Komatsu engine, disconnect ECM harnesses. • NEVER open any electrical cabinet covers or GE cards should be pulled forward far enough touch the Retarding Grid elements until all to disconnect card from backplane connector.
Page 434 Do not disconnect any power cables or use 3. Capacitor Charge Light them as hand or footholds. • Notify the Komatsu factory representative or Distributor immediately. If there is any question whether the system has potential hazardous voltage present, return to the operator cab and perform the normal shutdown procedure.
Page 435 NOTE: The following test procedures are applicable to Release 20 software. Procedures required for later software versions may vary. Contact the Komatsu distributor or factory representative for the current software version available. E03018 10/06...
Page 436 Battery Circuit Voltage Check: Resistance Checks, Low Voltage Circuits: 2. In the auxiliary control cabinet, measure voltage 3. Measure the resistance from ground to the to ground at each of the following circuits; 11, circuits listed in Table I. Stop and troubleshoot any 11B1, 712 @ TB32, and 11ST @TB28.
Page 437 Resistance Checks, Propulsion System Circuits: Chopper Modules (CM1, CM2): 4. Prepare for the following checks by performing 9. With the VOM set on the Rx10,000 scale, the following additional procedure: measure the following at each chopper module in the control cabinet: a.
Page 438: Table Ii
Battery and Control Circuit Checks - Battery Power ON TABLE II. POWER SUPPLY HARNESS RESISTANCE CHECKS Ohms Circuit Ohms Circuit return Make sure that the link voltage is drained down return before servicing propulsion system return performing tests. return 1. Prepare for the following checks by performing return the following procedure: return...
Page 439 Checks with Key Switch OFF 7. Verify the specified voltage to ground at the following locations in the auxiliary control cabinet: 5. With key switch OFF, verify 25VDC to ground +15VDC at the 15PV wire on TB29 (from TCI, minimum for the following circuits: supply to operator control pedals) +15VDC at the 15V wire on TB21 (from TCI, 11s onTB30...
Page 440 MEMORY BACKUP BATTERY TCI PROGRAMMING REPLACEMENT The replaceable memory backup battery on the CPU cards will require replacement if voltage is low when performing the CPU Battery Checks or if, during truck Make sure that the link voltage is drained down operation, an event code appears on the DID panel before servicing...
Page 441 PSC PROGRAMMING INVERTER PROGRAMMING Make sure that the link voltage is drained down Make sure that the link voltage is drained down and before servicing propulsion system the engine is not running before performing the performing tests. following procedures. 1. Connect the serial communication cable from the 1.
Page 442 PSC CHECKOUT To check the PSC digital inputs: Click START > Programs > GEOHVPTU_2.0 > PSC Digital Input Checks AC TOOLS > wPTU AC v21.01 1. Open circuit breakers 1 and 2 for gate driver Select “Normal” mode {enter} power converters 1 and 2. Type password “ok75e”...
Page 443 Close the “PSC Real Time Data” screen, then double-click “PSC Serial Data”. Verify that the analog and digital values are similar to the example in Figure 3-4. FIGURE 3-4. PSC SERIAL DATA SCREEN E03018 10/06 AC Drive System Electrical Checkout Procedure E3-13 (Release 21 Software)
Page 444 Close the “PSC Serial Data” screen, then With the retarder lever fully up (OFF position), double-click “PSC Analog Inputs”. verify that the “RETARD LEVER” signal is approximately 0 volts. Verify that the analog and digital values are similar to the example in Figure 3-5. With the retarder lever fully down, verify that the “RETARD LEVER”...
Page 445 Close the “PSC Analog Inputs” screen, then NOTE: All temperatures are calculated except for the double-click “PSC Temperatures”. AFSE and AMBIENT TEMPERATURE values. Verify that the temperature values are similar to Close the “PSC Temperatures” screen. the example in Figure 3-5. FIGURE 3-6.
Page 446: Table Iii
PSC Digital Output Checks To check the PSC digital outputs: 1. Open circuit breakers 1 and 2 for gate driver Click START > Programs > GEOHVPTU_2.0 > power converters 1 and 2. AC TOOLS > wPTU AC v21.01 2. Connect the serial communication cable from the Select “Normal”...
Page 447 TCI CHECKOUT TCI Digital Input Checks 1. Connect the serial communication cable from the PTU to the TCI port (DIAG3) on the DID panel located on the back wall of the operator cab. 2. Make sure that the directional control lever is in Make sure that the link voltage is drained down PARK and the rest switch is in the REST position.
Page 448 FIGURE 3-7. TCI REAL TIME DATA SCREEN E3-18 AC Drive System Electrical Checkout Procedure 10/06 E03018 (Version 21 Software)
Page 449: Table Iv
TABLE IV. TCI DIGITAL INPUT CHECKS STEP INPUT DESCRIPTION ENGSTRTREQ Engine Start Request - DO NOT CHECK AT THIS TIME. Check Engine Caution Lamp - Jumper circuit 419M @ TB30 to ground to illuminate the lamp in the overhead ENGCAUTION panel.
Page 450 Close the “TCI Real Time Data” screen, then double-click “TCI Serial Data”. Verify that the analog and digital values are similar to the example in Figure 3-8. FIGURE 3-8. TCI SERIAL DATA SCREEN E3-20 AC Drive System Electrical Checkout Procedure 10/06 E03018 (Version 21 Software)
Page 451 Close the “TCI Serial Data” screen, then double- With the accelerator pedal fully depressed, verify click “TCI Analog Inputs”. that the “ACCEL PEDAL” signal is approximately 8.5 volts. Verify that the analog values are similar to the example in Figure 3-9. With the RSC switch up (OFF position) and the RSC dial fully counterclockwise, verify that the With the accelerator pedal not depressed, verify...
Page 452 Close the “TCI Analog Inputs” screen, then NOTE: All temperatures are calculated except for the double-click “TCI Temperatures”. AFSE and AMBIENT TEMPERATURE values. Verify that the temperature values are similar to Close the “TCI Temperatures” screen. the example in Figure 3-10. FIGURE 3-10.
Page 453 TCI Digital Output Tests To check the PSC digital outputs: 1. Connect the serial communication cable from the Click START > Programs > GEOHVPTU_2.0 > PTU to the TCI port (DIAG3) on the DID panel AC TOOLS > wPTU AC v21.01 located on the back wall of the operator cab.
Page 454 To check the Engine Crank Signal: NOTE: Before checking ENGCRANK, verify that the 21B wires are removed from the starter solenoid relay in the battery control box. Also, make sure that the engine oil is at the proper level. 1. Change the PTU from the “Engine Stopped Tasks”...
Page 455: Table Vi
CALIBRATIONS The following procedures are used to calibrate the TABLE VI. CALIBRATION VALUES retarder and accelerator pedals, retarder lever, and the hydraulic brake temperature and propel system INPUT DESCRIPTION temperature gauges and the speedometer for the 0.00 - accelerator pedal released software.
Page 456 7. Close circuit breaker CB2 on GDPC1 in the right side compartment of the control cabinet. 1. Connect the serial communication cable from the PTU to the TCI port (DIAG3) on the DID panel 8. Use an analog meter to check the voltage located on the back wall of the operator cab.
Page 457 LOAD TESTING Click START > Programs > GEOHVPTU_2.0 > AC TOOLS > wPTU AC v21.01 Preparation Select “Normal” mode {enter} 1. Ensure that the wheels are chocked and the Type password “ok75e” {enter} directional control lever is in PARK. Under “Real Time”, double-click “PSC Real Time 2.
Page 458 Brake Circuit Switch Checks Hoist & Steering Circuit Switch Checks 1. Turn the rest switch ON. 9. On the inner side of the fuel tank, short circuit 39 on hoist circuit hydraulic filters bypass indicator 2. Start engine and allow engine to warm up for switch to ground.
Page 459 FIGURE 3-12. PSC REAL TIME DATA SCREEN FIGURE 3-13. PSC SERIAL DATA SCREEN E03018 10/06 AC Drive System Electrical Checkout Procedure E3-29 (Release 21 Software)
Page 460 FIGURE 3-14. PSC ANALOG INPUTS SCREEN 4. Make sure that the directional control lever is in Loadbox Test PARK and the rest switch is in the REST position. 5. Turn control power switch (1, Figure 3-1) and the key switch ON. 6.
Page 461 FIGURE 3-15. TCI REAL TIME DATA SCREEN FIGURE 3-16. INITIAL SELF LOAD ENGINE TEST SCREEN E03018 10/06 AC Drive System Electrical Checkout Procedure E3-31 (Release 21 Software)
Page 462 10. Note the ENGLOAD value on the screen. If the value is 5 volts during load testing, loading is satisfactory. If the value is below 5 volts, the electrical system In the following step, exhaust air from grid vents needs to remove horsepower loading. This is an may be very hot.
Page 463 FIGURE 3-17. TOTAL PARASITIC LOSS AT FULL POWER Komatsu SSDA16V160, 27000 GHP, ECS 8 Blade, 78” dia. 5.3” PW @ 798 RPM E03018 10/06 AC Drive System Electrical Checkout Procedure E3-33 (Release 21 Software)
Page 464 TROUBLESHOOTING Phase Module and Chopper Module Troubleshooting PVM Optimum Load Curve Handshaking 1. To troubleshoot a phase module or chopper Troubleshooting module, stop the engine and turn the rest switch NOTE: A value of less than 0.5VDC or more than OFF.
Page 465 PHASE MODULE REPLACEMENT Phase Module Removal Phase Module Installation 1. Place the control power switch in the OFF 1. Inspect the rear cooling air sealing gasket. position and the GF cutout switch in the CUTOUT Replace it if damaged. position. 2.
Page 466 NOTES E3-36 AC Drive System Electrical Checkout Procedure 10/06 E03018 (Version 21 Software)
Page 467 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX TIRES AND RIMS ..............G2 FRONT WHEEL HUB AND SPINDLE ASSEMBLY .
Page 468 NOTES G1-2 Index G01020...
Page 469 SECTION G TIRES AND RIMS INDEX TIRES AND RIMS ..............G2-3 FRONT TIRES AND RIMS .
Page 470 NOTES: G2-2 Tires and Rims G02022...
Page 471: Tires And Rims
TIRES AND RIMS The truck tires should be inspected and tire pressure FRONT TIRES AND RIMS checked with an accurate pressure gauge before Removal each working shift. Tire pressure will vary according to manufacturer and local working conditions. Con- sult tire manufacturer for recommended tire pres- sure.
Page 472 2. Turn the key switch OFF to stop the engine, and allow at least 90 seconds for the accumula- tor to bleed down. Turn the steering wheel to be sure no pressure remains. As a safety precau- tion, bleed down brake accumulators. Care should be taken not to damage the inflation 3.
Page 473: Installation
REAR TIRES AND RIMS Installation If the studs in the rear wheel motor require replace- NOTE: Remove all dirt and rust from mating parts ment, use a special tool and tighten studs to 540 ft before installing wheel assembly. lbs (732 N·m) torque. 1.
Page 474 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.) NOTE: Use care when removing spacer and inner wheel so as not to damage tire inflation extension tube.
Page 475: Installation
FIGURE 2-5. TIRE LIFTING SLING (BODY REMOVED) FIGURE 2-6. INNER TIRE REMOVAL AND Due to its size and weight, always keep person- INSTALLATION nel away from a wheel assembly when it is being removed and installed. 6. Secure inner and outer dual tire inflation lines to bracket on outer rim.
Page 476: Rim And Tire
2. Attach a hydraulic bead breaker to the rim by slipping the jaws of frame assembly over the outer edge of flange (5, Figure 2-8). Make sure the jaws of the frame are as far in on the flange as possible. 3.
Page 477: 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 478 6. Install outer flange (5, Figure 2-8) in position NOTE: allow paint, rust other and replace bead seat band (2). Push in on contamination to cover mating faces of lockring (6) bead seat band to expose O-ring groove in rim. and rim (3).
Page 479 SECTION G3 FRONT WHEEL HUB AND SPINDLES INDEX FRONT WHEEL HUB AND SPINDLE ..........G3-3 WHEEL HUB AND SPINDLE ASSEMBLY .
Page 480 NOTES: G3-2 Front Wheel Hub and Spindle G03029...
Page 481 FRONT WHEEL HUB AND SPINDLE WHEEL HUB AND SPINDLE ASSEMBLY Removal The following instructions will cover the complete removal, installation, disassembly, assembly and bearing adjustment of front wheel hub and spindle. If only brake service is to be performed, refer to Sec- tion "J", "Brake Circuit".
Page 482 8. Remove cap screws (1, Figure 3-2) securing Spindle Pusher Tool Usage retainer plate (2) to spindle structure and sus- pension. Loosen cap screws in torque incre- ments of 678 N·m (500 ft lbs). Remove retainer plate. 9. Carefully remove 13 of the steering arm cap Heavy structures and high forces are involved in screws (5) as follows: this procedure.
Page 483 2. After the tool has been installed, progressively increase the torque on the cap screws in a cir- cular pattern until the tapered piston breaks loose, or until the maximum specified torque on the cap screws of 2142 N·m (1580 ft lbs) is reached.
Page 484 3. Position spindle and wheel hub assembly on 9. Rotate the wheel hub to position the fill plug at fork lift or similar lifting device as shown in Fig- the 12 o'clock position. Remove the fill plug and ure 3-4. level plug.
Page 485 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 486 Disassembly 8. Remove face seal, bearing cone (19), and spacer (18) from spindle. Note: The preferred method for rebuilding the front 9. If brake disc replacement is required, attach a wheel hub and spindle assembly is to remove these lifting device to the brake disc (1, Figure 3-6), components as a complete unit, then support the remove cap screws (2), and lift and brake disc assemblies in a fabricated rebuild fixture, allowing...
Page 487 Assembly c. Check seal seat retaining lip for rough tool marks or nicks. Smooth any nicks and re- 1. If removed, install brake support, (13, Figure 3- clean. 5) to the spindle (17). d. Install rubber sealing ring so it seats uni- 2.
Page 488 7. If removed, install disc (1, Figure 3-6) on the 13. Install outboard pin (25, Figure 3-5) into slot on wheel hub using cap screws and flat washers spindle (17) and install inner bearing cone (9) (2). Lubricate the underside of cap screw (2) on spindle over pin (25).
Page 489 Wheel Bearing Adjustment (Tire Removed) 8. Assemble a shim pack to equal the dimension in step 6 within 0.025 mm (0.001 in.). 1. Install bearing retainer (1, Figure 3-9), without shims, with the thickness dimension stamp fac- NOTE: The above procedure results in a shim pack ing toward the outside.
Page 490 Wheel Bearing Adjustment (Tire mounted) 10. Tighten retainer cap screws alternately using the following procedure: The following procedure covers adjustment of front a. Tighten all cap screws to 81 N·m (60 ft lbs) wheel bearings while the tire and rim, hub, and spin- torque while rotating the hub.
Page 491 5,000 hours. ave. Depth(d ) - plate Thickness(t )=Shim Pack However, Komatsu will now allow the use of sched- uled oil sampling as an alternate method of monitor- = _______________ Shim Pack ing the front wheel bearings. Customers using this...
Page 492 5. When properly filled, the floating ball in the sight NOTE: For more information regarding oil sampling, gauge will be at its highest position. refer to the Komatsu Oil Wear Analysis (KOWA) 6. Replace the fill plug. manual. NOTE: The oil may need to be changed more frequently, depending on mine conditions and the results of the oil sample tests.
Page 493 STEERING CYLINDERS AND TIE ROD If premature wear of the bearings is evident, check the automatic lubrication system to ensure the proper The steering cylinders and tie rod are mounted in the amount of lubrication is being received at the joint(s) same manner.
Page 494 It is also important to ensure that steering linkage 3. Remove locknuts (9, Figure 3-12) cap screws, components are tightened to the proper torque. Use (3) and retainers (6 or 7) from both ends of the proper torque specifications listed in this section assembly.
Page 495 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. Cap Screw 17. Cap Screw 3. Cap Screw 8. Hardened Washer 13. Lockwasher 18. Locknut 4.
Page 496 TOE-IN ADJUSTMENT 1. The steering system must first be centered in the straight ahead position. Shut down engine and turn key switch OFF, and allow at least 90 seconds for the accumulator to bleed down. DO NOT turn steering wheel. Block front and back of rear wheels.
Page 497 SECTION G REAR AXLE HOUSING ATTACHMENT INDEX REAR AXLE HOUSING ATTACHMENT ..........G4-3 PIVOT PIN .
Page 498 NOTES: G4-2 Rear Axle Housing Attachment G04022...
Page 499 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) and pin and rear side of all tires.
Page 500 5. Install ground wire and lubrication line. Pressur- Assembly ize lube line to assure bearing receives grease. 1. Setup an appropriate tool to press spherical 6. Charge front suspension as described in Oiling bearing (4, Figure 4-2) into bearing carrier (13). and Charging Procedure, Section H.
Page 501 PIVOT EYE REPAIR Disassembly 1. Remove spherical bearing (4, Figure 4-2) as If damage occurs to the pivot eye (4, Figure 4-3), it may be necessary to remove it from the rear axle described in Pivot Eye Bearing, Disassembly. structure (1) to facilitate repair and bearing replace- 2.
Page 502 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 503 SECTION G REAR AXLE HOUSING INDEX REAR AXLE HOUSING ............G5-3 REAR AXLE HOUSING .
Page 504 NOTES: G5-2 Rear Axle Housing G05025...
Page 505 REAR AXLE HOUSING REAR AXLE HOUSING 6. Hook up lube lines on wheel motors. 7. Route electrical cables through cable grips on Removal right hand end of axle. 1. Remove the dump body as outlined in Section 8. Connect electrical cables to motorized wheels inside axle housing using identifications made at removal.
Page 506 Replace only with cap screws of correct up slack. Figure 5-1 illustrates use of an over- hardness. Refer to Komatsu Parts Catalog for correct head crane if the body has been removed. part number. Before installation, inspect each cap Remove cap screws securing wheel motor to screw for any defects and number of punch marks.
Page 507 1. Install two guide pins 180° apart in the rear 5. Insure wheel motor breathers are properly housing. installed. No sharp bends, or kinks in hoses are allowed in any line between the wheel motors and the breathers. Install wheel cover. 6.
Page 508 NOTES: G5-6 Rear Axle Housing G05025...
Page 509 SECTION H SUSPENSIONS INDEX FRONT SUSPENSION ............. . . H2 REAR SUSPENSION .
Page 510 NOTES H1-2 Index H01019...
Page 511 SECTION H FRONT SUSPENSION INDEX FRONT SUSPENSION ............. H2-3 Removal .
Page 512 NOTES: H2-2 Front Suspensions H02026...
Page 513 FRONT SUSPENSION 3. Discharge nitrogen pressure from suspension ® The HYDRAIR II suspensions are hydro-pneumatic by removing cap from charging valve (5, Figure components containing oil and nitrogen gas. The oil 2-1). Turn the charging valve swivel nut (small and gas in the four suspensions carry the gross truck hex) (3, Figure 2-2) counterclockwise 3 full weight less wheels, spindles and final drive assem- turns to unseat valve seal (DO NOT turn more...
Page 514 4. After all nitrogen pressure has been relieved, loosen large hex (4) and remove charging valve assembly. Discard flat gasket under large hex. FIGURE 2-2. CHARGING VALVE INSTALLATION 1. Valve Guard 4. Valve Body (Large 2. Valve Cap Hex) 3. Swivel Nut (Small Hex) 5.
Page 515 7. Attach fork truck or suitable lifting device to NOTE: The use of dry threads in this application is suspension. Secure suspension lifting not recommended. Due to the high tightening forces device. required to load these cap screws, dry threads may cause damage to tools.
Page 516 Turn-of-the-Nut tions. Replace only with cap screws of correct Tightening Procedure. After completing the hardness. Refer to Komatsu Parts Catalog for correct tightening procedure, continue with Steps 7-10 part number. Before installation, inspect each cap below.
Page 517 5. For the four inner, 330 mm (13 in.) long cap 7. Loosen the top two corner cap screws (1) and screws (6, Figure 2-3), tighten cap screws ini- the bottom outer four cap screws (8, the 4 bot- tially to 203 N-m (150 ft lbs) torque; then tom cap screws with nuts).
Page 518 MINOR REPAIR ONLY (Lower Bearing Structure & Seals) Bearing Structure Removal If only rod seals, O-rings, and backup rings (and if necessary, bearing structure) are to be replaced, refer to steps below for lower bearing structure removal. 1. Remove lower bearing structure cap screws and hardened washers (18 &...
Page 519 25. Rod Lip Seal 13. Roll Pin 26. Rod Wiper Seal MAJOR SUSPENSION REBUILD Disassembly NOTE: Refer to your Komatsu Distributor for ® HYDRAIR II repair information and instructions not covered in this manual. 1. With suspension held in a vertical position (end cap up), remove cap screws (1, Figure 2-5) and hardened washers (2).
Page 520 5. Remove cap screws and washers (18 & 19, Fig- ure 2-8). Install pusher bolts and remove lower bearing structure (16). 6. Remove and discard rod wiper seal (26) lip seal (25) and buffer seal (24). Remove and discard O-rings (20) and backup rings (21). Assembly NOTE: All parts must be completely dry and free of foreign material.
Page 521 PRESSURE TEST 8. Install upper bearing structure (6) onto piston rod. Secure bearing in place with NEW cap After rebuild is complete, suspension assembly screws (3) and hardened washers (4). Tighten should be tested for leakage. cap screws to 678 N-m (500 ft lbs) torque. NOTE: ALWAYS use new cap screws (3, Figure 2-7) during assembly.
Page 522 NOTES: H2-12 Front Suspensions H02026...
Page 523 SECTION H REAR SUSPENSIONS INDEX REAR SUSPENSIONS ............. H3-3 Removal .
Page 524 NOTES: H3-2 Rear Suspensions H03024...
Page 525 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 526 4. Place stands or cribbing under the truck frame 8. Remove locknuts (3, Figure 3-3) and cap at each hoist cylinder mount screws (2) at upper and lower pins (1) just on the suspension cylinder to be removed. 5. Open valve on suspension charging kit to release nitrogen from the suspension.
Page 527 17. Remove the cylinder from the truck. Clean the exterior of the suspension thoroughly and move to a clean work area for disassembly. 18. If it is necessary to remove the remaining rear suspension cylinder, insert the pins back into Do not exceed 10 tons of force when applying the upper and lower mountings.
Page 528 Installation 10. Service the suspension. For instructions, refer ® to HYDRAIR II Oiling and Charging Proce- 1. Inspect mounting bore sleeves (9, Figure 3-3) dure, this section. and bearing spacers for damage or wear. Check fit of pins in bores prior to installing sus- 11.
Page 529 FIGURE 3-6. REAR SUSPENSION ASSEMBLY H03024 Rear Suspensions H3-7...
Page 530 180°. Remove socket head cap screws NOTE: If other repairs are necessary, refer to your (18) and pull suspension piston assembly (5) local Komatsu Distributor for repair information and from housing (1). The housing bearing (21) will instructions not covered in this manual.
Page 531 PRESSURE TEST 3. Install the wiper seal (15, Figure 3-6), rod lip 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.
Page 532 NOTES: H3-10 Rear Suspensions H03024...
Page 533 SECTION H OILING AND CHARGING PROCEDURE INDEX OILING AND CHARGING PROCEDURE ..........H4-3 GENERAL .
Page 534 NOTES: H4-2 Oiling and Charging Procedures H04025...
Page 535: Hydrair
These procedures cover the Oiling and Charging of together). If rears are to be charged, the fronts ® HYDRAIR II suspensions on Komatsu Electric Drive should be charged first. Dump Trucks. NOTE: For longer life of suspension components, a Suspensions which have been properly charged will...
Page 536 ® 5. Attach charging valve adapters (2) to each sus- HYDRAIR CHARGING KIT pension charging valve stem. Assemble service kit as shown in Figure 4-1 and 6. Turn "T" handles (1) clockwise (this will depress attach to container of pure dry nitrogen (8). core of charging valve and open the gas cham- ber of the suspension).
Page 537 SUPPORT BLOCKS FOR OILING AND FRONT SUSPENSION CHARGING DIMENSIONS 1. Park the unloaded truck on a hard, level sur- face. Place the directional control lever in PARK. Place chock in front and behind two sets Prior to starting oiling and charging procedures, sup- of wheels to prevent roll away.
Page 538 1. Position and secure oiling height dimension blocks in place (Figure 4-2). When nitrogen pressure is released, suspensions will lower to rest on the blocks. Ensure the blocks do not mar or scratch the plated surfaces of the pis- tons or damage wiper seals in the lower bearing retainer.
Page 539 Front Suspension Nitrogen Charging 2. Tighten valve body (large hex, 6) to 16.5 ft lbs (22.4 N·m) torque. The valve swivel nut (small hex, 4) must be unseated by turning counter- clockwise three full turns. Lifting equipment (crane or hydraulic jacks) must be of sufficient capacity to lift the truck weight.
Page 540 REAR SUSPENSION 11. Close outlet valves (3) and remove charging kit components. Refer to Removal of Charging Kit. 1. Park the unloaded truck on a hard, level sur- face. Apply the parking brake, and chock the 12. If charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 5.4 N·m (4 ft lbs) torque.
Page 541 2. Remove charging valve cap. Turn the charging valve swivel nut (small hex) counterclockwise three full turns to unseat valve seal. DO NOT TURN LARGE HEX. The charging valve body has a bleeder groove in its mounting threads, but for safety of all personnel, the valve body MUST NOT be loosened until ALL nitrogen pressure has been vented from the suspension.
Page 542 1. If removed, install charging valve with new O- NOTE: A low left front suspension will cause the right ring (9, Figure 4-3). Lubricate the O-ring with rear suspension to be high. A low right front ® suspension will cause the left rear suspension to be clean HYDRAIR oil.
Page 543 OIL AND NITROGEN SPECIFICATIONS CHART ® HYDRAIR II OIL SPECIFICATIONS Ambient Temperature Part No. Approved Sources Range VJ3911 Mobil 424 Sunfleet TH Universal Tractor Fluid (need to add Mobil D.T.E. 15 Chevron Tractor Hydraulic Fluid- 6% of Texaco TDH Oil Conoco Power Tran III Fluid -30°F &...
Page 544 NOTES: H4-12 Oiling and Charging Procedures H04025...
Page 545: Brake Circuit
SECTION J BRAKE CIRCUIT INDEX BRAKE CIRCUIT..............J2-1 BRAKE CIRCUIT COMPONENT SERVICE .
Page 546 NOTES: J1-2 Index J01038...
Page 547 SECTION J2 BRAKE CIRCUIT INDEX BRAKE CIRCUIT ..............J2-3 OPERATION .
Page 548 NOTES: J2-2 Brake Circuit J02037...
Page 549: Brake Circuit
BRAKE CIRCUIT OPERATION The remainder of the system, including the brake manifold, circuit accumulators, and electrical compo- The 830E truck is equipped with hydraulic actuated nents, are located in a weatherproof cabinet behind disc brakes. The front brakes have three calipers the cab.
Page 550 FIGURE 3-1. 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 551: Secondary Braking And Automatic Apply
SECONDARY BRAKING AND Normal Operation (key switch on, engine run- AUTOMATIC APPLY ning) A fundamental function of the brake system is to pro- • Directional Control Lever in Park Position vide reserve braking in the event of any single failure. The parking brake solenoid (16) is de-energized.
Page 552: Brake Lock Circuit
BRAKE LOCK CIRCUIT • Brake Lock Degradation Switch (9, Figure 2-1) Located on the junction block (10) in the brake The primary function of the brake lock is to provide a cabinet. When the brake lock switch is turned means for the operator to hold the vehicle while at ON, the brake warning light relay is energized.
Page 553 FIGURE 3-2. 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 554 FIGURE 3-3. BRAKE VALVE (PARTIAL CUT-AWAY) 1. Actuator Base 2. Brake Valve 3. Orfice Set-Screw J2-8 Brake Circuit J02037...
Page 555 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX BRAKE CIRCUIT COMPONENT SERVICE ..........J3-3 BRAKE VALVE .
Page 556 HYDRAULIC BRAKE ACCUMULATORS ......... J3-19 Brake Accumulator Bleed Down Procedure .
Page 557 BRAKE CIRCUIT COMPONENT SERVICE BRAKE VALVE The brake valve is a pressure modulating valve, actuated mechanically (brake pedal) or hydraulically through the automatic apply valve (12, Figure 3-1). The Brake Valve independently controls the pressure delivered to the front and rear service brake assem- blies.
Page 558 3. Remove access panel in front of operator's cab. 4. Tag and remove all hydraulic lines from brake valve. Plug lines and ports to prevent possible contamination. Remove all valve fittings. 5. If equipped, remove retard pedal that is located Before disabling brake circuit, be sure truck on brake pedal.
Page 559 6. In the cab at the brake valve, remove cap NOTE: best performance, charge screws and lockwashers securing the brake accumulators in the temperature conditions the valve assembly to the mounting structure. vehicle is expected to operate in. During the precharge, allow temperature of the nitrogen gas to 7.
Page 560 FIGURE 3-3. BRAKE VALVE WITH RETARD PEDAL 1. Brake Valve 7. Nylon Bearing 12. Pedal Structure 17. Brake Pedal Actuator 2. Retainer Clip 8. Pivot Shaft 13. Pad 18. Spring Pivot (Lower) 3. Pivot Shaft 9. Place 0.010 in. Shim 14.
Page 561 DISASSEMBLY 5. Remove the four button head allen screws (3, Figure 3-4) securing the boot retainer plate (4). NOTE: If equipped with, and not already removed, 6. Remove the boot retainer plate (4), boot (2), remove electronic retard pedal (16, Figure 3-3) from and actuator cap (1) as an assembly by grasp- brake pedal by removing pivot shaft (8).
Page 562 FIGURE 3-5. BRAKE VALVE 1. Adjustment Collar 9. Back-up Ring 17. Reaction 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.
Page 563 4. Inspect each spring carefully for cracks or NOTE: Throughout the following steps, it is important breaks. Any spring with a crack or break must to keep the circuits and circuit components identified be replaced. Also, if the valve was not reaching as to which side of the unit they came from.
Page 564 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 Regulator Sleeve O-Ring Installation FIGURE 3-6. VALVE BODY SEAL INSTALLATION 1. Install O-ring (2, Figure 3-7) onto the smallest 1. Actuator Plunger 4.
Page 565 Actuator Plunger O-ring Installation 5. Lightly lubricate the regulator spool (8). 6. Install the regulator spool into the regulator 1. Install an O-ring (3, Figure 3-5) into the O-ring sleeve (14). The spherical end of the spool groove located at the large diameter end of the should be at the top of the regulator sleeve.
Page 566 10. Install the spool return spring (15) into spool (8). 16. Install the base plate (27) on top of the retainer plug. Tighten the four allen screws (29) evenly, 11. Insert reaction plunger (16 or 17) into regulator alternating diagonally, to evenly seat the regula- spool.
Page 567 VALVE BENCH TEST AND ADJUSTMENT • Hose fittings for valve ports: Port PX is 7/16 in. - 4 SAE. The following parts and test equipment will be Ports P1, P2, B1 and B2 are 3/4 in. - 8 SAE. required to completely bench test and adjust the dual Port T is 1 1/16 in.
Page 568 Test Set Up Procedure Brake Valve Output Pressure Adjustment 1. Position the valve in the fixture to allow plung- 1. Install the pedal pivot shaft pin in the actuator ers to be activated by hand using a lever (refer base by itself without installing the pedal to Figure 3-9).
Page 569 9. Recheck pressures after cycling. If they have 13. With test stand pump adjusted for 22 064 kPa changed, re-adjust pressures. (3,200 psi) or with engine running and brake system supply pressure at or above 20 685 kPa 10. Shut down the test bench and relieve all (3,000 psi), depress the pedal as quickly as hydraulic pressure from the lines.
Page 570 21. Fully stroke the brake pedal actuator to check 23. Check internal leakage at port "T". Leakage that output pressure at port "B1" and "B2" are must be less than 100 cc/minute with the valve within specifications. in the released position and system pressure supplied to the "P1"...
Page 571 Installation Of Brake Pedal Actuator Assembly to Brake Valve 1. Install jam nut (9, Figure 3-10) and set screw (10) to brake pedal actuator (7). 2. Insert nylon bushings (4) into brake pedal actu- Be sure to install spring assembly correctly, with ator.
Page 572 BRAKE ASSEMBLIES WITH INTEGRAL 1. Install nylon bearings (7, Figure 3-11) in retard MOUNTED ELECTRONIC RETARD PEDAL pedal. (Dual Function Pedal) 2. Install retard pedal (16) to brake pedal actuator (17) with pivot shaft (8). Install two retainer clips Installation of Retard Pedal To Brake Pedal (6).
Page 573 HYDRAULIC BRAKE ACCUMULATORS There are two hydraulic brake accumulators located on the brake manifold in the brake control cabinet behind the operator's cab. Both accumulators are 9.51 l (2.5 gal) capacity. The right one supplies the pressure necessary for actuation of the front service brakes.
Page 574 4. Remove locknut from plug and poppet assem- bly using a spanner wrench and an adjustable wrench. One for torque and one for counter- torque to prevent the poppet assembly from rotating. (Refer to Figure 3-13). 5. Remove spacer, Figure 3-14. 6.
Page 575 8. Hold bladder valve stem on the flats with a or damage new seals. If this area is pitted con- wrench and tighten nut (5) securely. sult your Komatsu Service Manager. Assembly Assemble the accumulator in a dust and lint free area.
Page 576 11. Withdraw threaded end of plug through shell 15. Install O-ring over plug and poppet assembly opening. (Refer to Figure 3-20). and push until seated. DO NOT TWIST O-RING. 16. Install spacer with smaller diameter of the shoulder toward shell. 17.
Page 577 Charging Procedure 4. Proceed to inflate accumulator to 9653 ± 345 kPa (1400 ± 50 psi) pressure by slowly opening 1. Mount hose assembly gland nut on pressure the pressure regulator valve on nitrogen cylin- regulator. der, closing it occasionally to allow needle on pressure gauge to stabilize (thus giving accu- rate reading of precharge pressure).
Page 578 BRAKE MANIFOLD Removal If the brake manifold is leaking oil, a single O-Ring or cartridge can be replaced while the manifold is still located on the truck. See the DANGER warning below. Accumulators maintain high pressure. DO NOT disconnect any hydraulic line or perform any ser- vicing on any brake system component(s) until all hydraulic pressure has been manually drained from accumulators.
Page 579 9. If the manifold has to be removed from the Assembly truck, remove accumulators and disconnect 1. Install new O-rings on all components that were hydraulic lines and wires necessary to allow removed from the manifold. removal of the manifold. 2.
Page 580 NOTES: J3-26 Brake Circuit Component Service J03034...
Page 581 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING ......J4-9 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET ..J4-12...
Page 582 NOTES: J4-2 Brake Circuit Check-Out Procedure J04036...
Page 583 BRAKE CIRCUIT CHECK-OUT PROCEDURE The brake circuit hydraulic pressure is supplied from NOTE: If internal leakage within the steering circuit is the steering circuit at the bleed down manifold. Some excessive, this also may contribute to problems brake system problems, such as spongy brakes, within the brake circuit.
Page 584 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 wait- bottom side of the bleeddown manifold (refer to ing 90 seconds.
Page 585 EQUIPMENT REQUIRED Included on the last page of this module is a data BRAKE CIRCUIT ABBREVIATIONS sheet to record the information observed during the Automatic Apply Pressure hydraulic brake system check-out procedure. The data sheet can be removed, copied, and used during Accumulator, Front Brake the check-out procedure.
Page 586 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 587 BRAKE SYSTEM CHECK-OUT BRAKE LOCK 17. Disconnect wire harness from brake lock sole- NOTE: Unless otherwise specified, perform the noid, located on brake manifold in hydraulic following checks with engine running, the directional cabinet, and to the right of the PK2 port. control lever in PARK and brake lock released.
Page 588 FAILURE MODES CHECK-OUT 27. Start engine to recharge hydraulic system. Allow engine to run until low brake accumulator 23. Allow engine to run until low brake accumulator pressure stabilizes at or above 22,064 kPa pressure stabilizes at or above 22,064 kPa (3,200 psi).
Page 589 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 590 TROUBLE: A Low Brake Pressure Warning Occurs When Brakes are Applied Leak or other malfunction in one brake circuit. Inspect brake system and repair leaks. Brake valve balance is out of adjustment. Adjust collars according to instructions. TROUBLE: The Low Pressure Warning Circuit Not Operating Properly The Low Brake Pressure lamp is burned out.
Page 591 TROUBLE: Oil is Leaking Around the Pedal Base Defective seal on top of brake valve. Replace the seal. TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM Excessive internal leakage in a component. Check all steering and brake system components.
Page 592 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 _______________ Front brake accumulator charged to 9653 kPa (1400 psi).
Page 593 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET STEP 15 _______________ Front brake circuit pressure, pedal completely released - 0. _______________ Rear brake circuit pressure, pedal completely released - 0. Brake Lock STEP 19 _______________ Low brake lock pressure warning alarm actuation - 6895 ± 172 kPa (1000 ± 25 psi).
Page 594 NOTES J4-14 Brake Circuit Check-Out Procedure J04036...
Page 595 SECTION J5 FRONT BRAKES INDEX ROCKWELL WHEEL SPEED FRONT DISC BRAKES ........J5-3 BRAKE CALIPER .
Page 596: Rockwell Wheel Speed Front Disc Brakes
NOTES J5-2 Rockwell Wheel Speed Front Disc Brakes 10/06 J05024...
Page 597: Brake Caliper
ROCKWELL WHEEL SPEED FRONT DISC BRAKES BRAKE CALIPER Caliper Removal Each front wheel speed brake assembly has three* 1. Remove front tires and rims according to proce- 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 598: Installation
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 599: Disassembly
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 600: Cleaning And Inspection
Cleaning and Inspection 5. Inspect piston cavities for evidence of varnish formation, caused by excessive and prolonged 1. Preliminary cleaning can be more effective if lin- heating of brake oil. ings are first removed. However, retaining plates should be temporarily reinstalled in order to stay with brake assembly through overhaul cycle.
Page 601: Brake Lining
BRAKE LINING 7. Inspect piston cavities for damage similar to Step 6 above, with particular attention to the Replacement edge of the seal grooves. These must feel smooth and sharp with no nicks or sharp projec- Each front wheel speed disc assembly has three tion that can damage seals or scratch pistons.
Page 602 8. If original linings have sufficient lining material for reuse, inspect lining back plate for cracks or excessive yielding where plate fits into end plates 7 or 8 (Figure 5-3). When replacing linings, never mix new and used linings in a brake assembly. 9.
Page 603: Front Service Brake Conditioning (Burnishing) Procedure
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE GENERAL Front Brake Conditioning After any brake lining replacement, or at new truck 1. To prevent overheating and possible destruc- tion of rear brakes, temporarily disconnect the start up, the brake linings and discs must be bur- REAR brakes while burnishing front wheel nished.
Page 604 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 605 SECTION J6 ARMATURE SPEED REAR DISC BRAKES INDEX ARMATURE SPEED REAR DISC BRAKES ..........J6-3 REAR BRAKES .
Page 606 ASSEMBLY ..............J6-20 Adjuster and Pin Assembly .
Page 607 ARMATURE SPEED REAR DISC BRAKES REAR BRAKES 2. With engine off, key switch OFF, wait 90 sec- onds for steering accumulators to bleed down. Each rear wheel service brake assembly consists of Open both brake accumulator drain valves. two discs, each with a four piston caliper and a lining 3.
Page 608 10. Remove cap screws and flat washers (9). Remove adapter (10). Remove inner caliper half from adapter (2). 11. Remove the two center caliper mount cap screws (13) from inboard caliper (14) and install two 7/8-9 NC X 14 in. studs. 12.
Page 609 Installation d. Make a measured shim pack equal to the result obtained in Step 4c. If not equal, then within 0.127 mm (0.005 in.) of the result. This will be brake disc shim pack (7). 5. Remove disc mounting cap screws (11) and inner disc (12).
Page 610 16. With brake linings secured to caliper with wire, NOTE: If the brake lining moves away from the cali- install inner brake caliper half (5) over the two per while handling during installation, the caliper studs. Ensure brake bleeder plug (3, Figure 6-3) must be partially disassembled to re-adjust the park- is installed in the location shown.
Page 611 Adjustment 5. Parking brake adjustment occurs automatically when the parking brake is released and the ser- 1. Block wheels to prevent truck movement. vice brake is applied. 2. Start engine and operate at low idle speed. 6. Move directional control lever to PARK. 3.
Page 612 CALIPER 6. Separate the two lining end plates from the cali- per housing half by removing the six cap screws Disassembly (1, Figure 6-5), three from each end plate. 1. Open all bleeder screws and allow the fluid to drain from the assembly into an approved con- tainer.
Page 613 9. Remove the four spring washers (1, Figure 6-7) 12. Pull the adjusting bolt (1, Figure 6-9) from the from the parking piston cavity of the caliper collar inside the parking pistons of each caliper housing. housing. FIGURE 6-9. PARK PISTON FIGURE 6-7.
Page 614 15. Use a suitable tool to push the parking piston 18. Position the caliper housing so that the ends of out of the caliper housing. the adjuster pin and nut are up. Use a 5/32-inch Allen wrench to hold the pin and remove the nut 16.
Page 615 PISTON SUBASSEMBLY 21. Use a suitable tool to remove the 76.2 mm (3 in.) diameter service piston O-ring (1, Figure 6- Disassembly 15) and backup ring (2) from each piston bore groove of the caliper housing. Discard the O- NOTE: Disassembly of the piston subassembly rings and backup rings.
Page 616 PREPARATION FOR ASSEMBLY 4. Back out the threaded ring. Use a spanner wrench if the threaded ring will not unscrew by hand. 5. Slowly raise the arbor until all compression of the piston return spring is relieved. 6. Remove the spring retainer, return spring, outer Read and observe all Warning and Caution haz- spring guide, adjusting pin with adjuster assem- ard alert messages in this publication.
Page 617 INSPECTION For Rough Metal Parts Use a cleaning solvent or a weak alkaline solution in Caliper Parts a hot solution tank to clean rough metal parts. If a hot 1. inspect the pistons, housing bores and O-ring solution tank is used, follow the instructions below. grooves for scratches or corrosion.
Page 618 PISTON ASSEMBLY RETURN SPRING Shoes, Linings and End Plates FORCE AND BUILT-IN CLEARANCE (BIC) To help prevent abnormal lining wear, replace worn, bent or cracked end plates and distorted shoes. Inspect the end plate cap screws for wear. Replace 1. Place the piston subassembly onto a spring the bolts if worn.
Page 619 4. Hold the spring compressed and rotate the indi- Piston Assembly Adjuster Grip Force cator dial to indicate ZERO. 1. Inspect the piston assembly adjuster grip force. 5. Raise the arbor slowly until the spring tester This is the force required to cause the adjuster force scale reads ZERO;...
Page 620 Do not use a commercially available spring tester for making adjuster force measurements. Sud- den adjuster force release can damage such a tester, requiring repair and re calibration. NOTE: If a suitable hydraulic shop press is available, the calibrated spring pod (4, Figure 6-20) is unnecessary.
Page 621 4. Insert the piston assembly into the adjuster pin 1. Place the spring pod on the arbor press table. extender tool and secure firmly using the Use both special sleeves, Figures 6-26 as knurled nut on the threads of the adjuster pin. shown in Views A and B of Figure 6-21 to slip Place the special tool and piston assembly the adjuster back and forth several times on the...
Page 622 a. Place the adjuster and pilot pin subassembly NOTE: Any rework of the adjuster pin must be onto the end of the adjuster pin. avoided unless absolutely necessary. b. Press the adjuster off the expendable pilot pin, onto the adjuster pin. See Figure 6-22. 4.
Page 623 Piston Return Spring 3. Set up the dial indicator between the tester arbor and the table. Place the outer spring 1. Inspect the return spring for a free height guide under the tester arbor. Lower the arbor dimension of 22.15 mm (0.872 in.). A measured firmly onto the spring guide.
Page 624 ASSEMBLY 1. Place the adjuster and pilot pin subassembly onto the end of the adjuster pin. 2. Press the adjuster (4, Figure 6-24) off the Read and observe all Warning and Caution hazard expendable pilot pin onto the adjuster pin. alert messages in this publication.
Page 625 Piston Subassembly 8. Screw the threaded ring against the spring retainer, using a spanner wrench to ensure that 1. Install inner spring guide (10, Figure 6-25) into the threaded ring is bottomed. Holding the the piston cavity. spring compressed, back off the threaded ring 2.
Page 626 If the wrong components are installed, the caliper will not operate correctly and can cause damage to the equipment. Use of non Komatsu (OEM) parts can cause damage, loss of braking and serious personal injury. 1. Position the housings onto a work surface so that the cylinder bores are up.
Page 627 12. Install a new smaller diameter 63.5 mm (2.5 in.) 14. Install a new larger diameter 127 mm (5 in.) parking piston backup rings (2, Figure 6-28) into parking piston backup ring (2, Figure 6-29) into the ring groove of each caliper housing. the outer groove of each parking piston.
Page 628 17. Install the two parking pistons (3, Figure 6-30) 20. Install snap ring (2, Figure 6-31) into the snap into the parking piston bore of each caliper ring groove of each parking piston inner bore to housing until fully seated. The smaller diameter retain the adjusting collars.
Page 629 22. Screw the adjusting bolt (1, Figure 6-32) into the 25. Install end plates (2, Figure 6-33) and end plate adjusting collar finger tight, until fully seated into cap screws into each caliper half. Tighten the the parking piston. cap screws to 515-624 N·m (380-460 ft lb). 23.
Page 630 28. Install the spring onto the shoulder bolt. Insert 31. Install four spring washers (1 & 2, Figure 6-35) the shoulder bolt and spring (1, Figure 6-34) onto the surface of each parking piston. into the adjusting bolt (3). 29. Using a long 3/16-inch (4.763 mm) Allen wrench, align the backing plate threaded hole with the shoulder bolt and install the shoulder bolt and tighten to 13.6-17.0 N·m (120-150 in.
Page 631 32. Using a suitable spanner wrench, install the parking piston cap (1, Figure 6-36) into each caliper housing. Tighten to a minimum of 339 N·m (250 ft lb). 33. Using a suitable Allen wrench, install the pipe plug into the center hole of each parking piston cap.
Page 632 PERIODIC INSPECTIONS Inspect the following areas for fluid leaks. Inspect the caliper, linings and disc on a periodic • Pistons. If fluid leaks at a piston, disassemble the schedule. caliper. Inspect the piston, bore, O-rings and backup rings. Service as necessary. •...
Page 633 BRAKE LINING BRAKE DISC Replacement Inspection Inspect brakes periodically for wear. Linings must be Inspect brake discs for wear. replaced when lining material has been worn to a 1. Place a straight edge across face of disc and minimum of 3.2 mm (0.125 in.). Use of linings measure from straight edge to worn face.
Page 634 • BEFORE DISCONNECTING PRESSURE must be performed each time a new set of brake lin- LINES, REPLACING COMPONENTS IN THE ings are installed, or before a new Komatsu Truck is HYDRAULIC CIRCUITS, INSTALLING put into operational service. A surface pyrometer is...
Page 635 Rear Brake Conditioning NOTE: The Override Switch on the instrument panel must be depressed and held by the operator in order Note: Front brakes will require burnishing to propel the truck with the brakes applied. independently from rear brakes in order to control disc temperatures.
Page 636 BRAKE BLEEDING PROCEDURE a. Maintaining partial application, open bleeder valve until a clean stream of oil is discharged Attach brake lines and bleed brake calipers accord- from caliper. Use bleeder valves shown in ing to the following instructions: Figure 6-39. NOTE: Bleeder valves must be installed in the b.
Page 637 SECTION L HYDRAULIC SYSTEM INDEX HYDRAULIC SYSTEM ............L2 HYDRAULIC COMPONENT REPAIR.
Page 638 NOTES L1-2 Index L01041...
Page 639: Hydraulic System
SECTION L HYDRAULIC SYSTEM INDEX HYDRAULIC SYSTEM ............. .L2-3 HYDRAULIC SYSTEM OPERATION .
Page 640 NOTES: L2-2 Hydraulic System L02043...
Page 641 HYDRAULIC SYSTEM HYDRAULIC SYSTEM OPERATION The following describes the basic hydraulic system The service capacity of the tank is 901 l (238 gal.). operation. Further system description is outlined Type C-4 hydraulic oil is recommended for use in the under different system circuits such as the hoist cir- hydraulic system.
Page 642 HIGH PRESSURE HYDRAULIC FILTERS The truck is equipped with high pressure hydraulic oil filters to filter the oil supply at the outlet of the pumps. The steering/brake system filter (4) and two hoist cir- cuit filters (4, Figure 2-1) are located on the right When servicing the hydraulic system, relieve side, behind the fuel tank.
Page 643 DISABLED TRUCK CONNECTORS The steering circuit and hoist circuit relief valves are adjusted to 17 240 kPa (2500 psi). The brake system Quick disconnect fittings are provided to allow opera- relief is adjusted to 24 132 kPa (3500 psi). tion of the steering and brake circuits for temporary truck operation if the steering/brake pump is not Refer to the appropriate information in this section of operational.
Page 644 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 645 SECTION L HYDRAULIC SYSTEM COMPONENT REPAIR INDEX HYDRAULIC SYSTEM COMPONENT REPAIR ......... .L3-3 HOIST PUMP .
Page 646 NOTES: L3-2 Hydraulic Component Repair L03039...
Page 647 HYDRAULIC SYSTEM COMPONENT REPAIR HOIST PUMP 2. Drain the hydraulic tank by use of the drain Removal valve (12, Figure 3-1) located on the bottom of the tank. NOTE: It is not necessary to remove the steering pump with the hoist pump. The steering pump may NOTE: If oil in the hydraulic tank has not been be disengaged and supported as the hoist pump is contaminated, the shut-off valves can be closed and...
Page 648 4. Disconnect and remove the hose at the alterna- 11. Make sure the lifting and support devices are in tor end and swing clear of work area. place on both pumps. Loosen (but do not remove) the rear support bracket cap screws 5.
Page 649 4. Attach front support bracket to the “T” bracket 8. Service the hydraulic tank with C-4 type hydrau- and to the pump with cap screws, lockwashers lic fluid. Refer to Hydraulic Tank, this section for and nuts. Tighten cap screws to standard filling instructions.
Page 650 Disassembly 5. Remove nuts (17, Figure 3-2) and remove bear- ing plate (6) with transition plate (8) and O-ring NOTE: As parts are removed they should be laid out (4). Remove cap screws (5) securing the bear- in a group in the same order in which they are ing plate to the transition plate and remove removed.
Page 651 9. Remove bearing plate (2). Remove O-ring (23) 13. Unthread the thru studs (12) and remove. and stud O-rings (1). Remove dowels (20) if Remove flange (5), if stuck tap flange lightly damaged or replacement of the bearing plate is with a plastic hammer to loosen.
Page 652 NOTE: To aid in shaft seal removal place the flange on two small wooden blocks, refer to Figure 3-5. 16. Use a punch and hammer and tap the outboard shaft seal out of the flange bore. (Refer to Fig- ure 3-6.) Use care not to mar, scratch or dam- age the seal bore surface, or bearings.
Page 653 Inspection Of Parts 5. Inspect the bearings, if they are worn beyond the gray teflon into the bronze material, the 1. Examine the gear bores in both gear plates, ref- complete flange connector plates or bearing erence Figure 3-7. During the initial break-in, plate should be replaced.
Page 654 Assembly 6. Position the press ring over the seal. Make sure that the seal stays centered and true with the 1. A suitable seal press ring or plug and two small bore, and start applying pressure with the vise. wood blocks should be available. Continue pressing the seal until it just clears the 2.
Page 655 9. Lubricate the thru stud threads (14, Figure 3-9) 10. Install steel rings (5, Figure 3-10). Lubricate and with hydraulic oil. Thread the studs into flange install backup ring (8), O-ring (7) and ring until snug. There are 4 long studs and 4 short retainer (6) as shown in Figure 3-10.
Page 656 14. With the extension end of the drive gear facing NOTE: To ensure the gear pump is correctly timed toward the shaft seals, install the drive gear. Do during reassembly, place a mark on the end of the not drop the gear in the bore as damage to the input shaft to indicate the location of the valley bronze face of the pressure plate could result.
Page 657 16. Install steel rings (11, Figure 3-13), backup ring 17. Lubricate and install thru stud O-rings (5) and (12), O-ring and retainer (13). Install isolation connector plate O-ring (7). Install dowel (14) if plate with its relief toward the pressure plate. removed.
Page 658 18. Lubricate O-ring (3, Figure 3-14) and install in 20. Lubricate I.D. of bearings (18, Figure 3-14). bearing plate (7). Lubricate O-rings (4) and Install O-rings (8 & 9) and dowel (25) if install over studs (12). Replace dowel (2) if removed.
Page 659 22. Repeat steps 15 and 16 for installation of the 31. Install a new O-ring on steering pump flange remaining pressure plate, steel rings, backup and install steering pump to the transition plate ring, O-ring, and retainer and isolation plate. (16, Figure 3-14).
Page 660 HYDRAULIC TANK 3. Replace fill cap. 4. Start engine, raise and lower the dump body Filling Instructions three times. NOTE: If filling is required, use only type C-4 5. Continue to repeat steps 1 thru 4 until oil level is hydraulic oil as specified on the truck Lubrication maintained in the top sight gauge with the Chart.
Page 661 HYDRAULIC TANK STRAINERS 4. Disconnect hydraulic lines. Plug lines to prevent possible contamination to the system. Tag each Removal line at removal for proper identification during installation. 5. Attach a lifting device to the hydraulic tank. 6. Remove the cap screws and lockwashers securing the hydraulic tank mount caps to the frame.
Page 662 Installation 1. Install suction strainers and secure in place with cap screws and lockwashers. Tighten cap screws to standard torque. 2. Using new cover gasket, install cover and secure in place using cap screws and lock- washers (4, Figure 3-17). Tighten cap screws to standard torque.
Page 663 HOIST CIRCUIT FILTERS Two hoist circuit filters (Figure 3-18) are located on the fuel tank below the right frame rail. The filters pro- vide secondary filtering protection for hydraulic oil flowing to the hoist valve and hoist circuit compo- nents. An indicator switch (5) is designed to alert the opera- tor of filter restriction before actual bypass occurs.
Page 664 FILTER ELEMENT REPLACEMENT Installation 1. Install new element (9). Install new O-ring (6) and backup ring (7). 2. Install bowl on filter head and tighten. Lock in place with setscrew (8). 3. Install bottom plug (13), and bleed plug (11). Relieve pressure before disconnecting hydraulic and other lines.
Page 665 SECTION L STEERING CIRCUIT INDEX STEERING CIRCUIT ............. . .L4-3 STEERING CIRCUIT OPERATION .
Page 666 NOTES: L4-2 Steering Circuit L04048...
Page 667 STEERING CIRCUIT STEERING CIRCUIT OPERATION The accumulator oil is supplied constantly to the flow amplifier, via the bleed down manifold. The accumu- The steering/brake pump (2, Figure 4-1) delivers oil lators also act as a reservoir for pressurized hydrau- to the high pressure steering filter (7), then to a bleed lic oil to be used during an emergency situation down manifold valve (4) which is located on the should the hydraulic steering oil supply malfunction...
Page 668 COMPONENT DESCRIPTION Hydraulic oil flows to the closed center steering valve STEERING CONTROL UNIT via the flow amplifier. The flow amplifier is pilot-con- trolled by the steering valve. Due to large oil dis- The steering control unit is located behind an access placement in the steering cylinders, the flow amplifier cover on the front of the operator's cab.
Page 669 FIGURE 4-2. FLOW AMPLIFIER L04048 Steering Circuit L4-5...
Page 670 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 671 FIGURE 4-3. FLOW AMPLIFIER (No Steer) L04048 Steering Circuit L4-7...
Page 672 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 673 FIGURE 4-4. FLOW AMPLIFIER (Steering Left) L04048 Steering Circuit L4-9...
Page 674 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 675 FIGURE 4-5. FLOW AMPLIFIER (Steering Right) L04048 Steering Circuit L4-11...
Page 676 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 677 FIGURE 4-6. FLOW AMPLIFIER (No Steer, External Shock Load) L04048 Steering Circuit L4-13...
Page 678 BLEED DOWN MANIFOLD The relief valves, accumulator bleed down solenoids, and steering pressure switch are not individually The bleed down manifold (10, Figure 4-7) is located rebuildable and are factory preset. Refer to Steering on the inside of the left hand frame rail just behind Circuit Check-Out Procedure for relief valve setting.
Page 679 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 9653 kPa (1400 the steering and brake circuits. psi) 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 680 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 681 FIGURE 4-9. CUT-AWAY VIEW OF STEERING PUMP L04048 Steering Circuit L4-17...
Page 682 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 683 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 684 NOTES L4-20 Steering Circuit L04048...
Page 685 SECTION L STEERING CIRCUIT COMPONENT REPAIR INDEX BLEED DOWN MANIFOLD ............L5-3 Removal .
Page 686 STEERING CYLINDER ............L5-25 Disassembly .
Page 687 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 688 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 689 6. Connect a lifting device to the top section of the Installation accumulator and take up slack. The accumulator weighs approximately 140 Kg The accumulator weighs approximately 140 Kg (310 lbs). Use a suitable lifting device that can (310 lbs). Use a suitable lifting device that can handle the load safely.
Page 690 Any nicks or damages in pull rod. this area could destroy the accumulator bladder or damage new seals. If this area is pitted con- sult your Komatsu Service Manager. L5-6 Steering Component Repair L05035...
Page 691 7. Hold bladder valve stem on the flats with a 12. Connect nitrogen charging kit to charging valve. wrench and tighten nut (5) securely. Refer to “Steering Accumulator Charging Pro- cedure” to charge accumulator. With hydraulic 8. If removed, install pressure switch (15), valve port assembly firmly in place, slowly pressurize assembly (11) and charging valve onto gas the bladder using dry nitrogen with sufficient...
Page 692 LEAK TESTING To carry out the testing required, it will be necessary to check for internal and external leaks at high pres- sure. A source of 24 132 kPa (3500 psi) hydraulic pressure and nitrogen pressure of 9653 kPa (1400 Do not twist O-ring.
Page 693 STEERING ACCUMULATOR CHARGING 3. Remove charging valve cover (5, Figure 5-3). PROCEDURE 4. Close all valves (1, 2 & 8, Figure 5-7). 5. Install charging manifold assembly to the nitro- gen gas supply tank. Open valve on nitrogen supply tank. Do not loosen or disconnect any hydraulic line or component until engine is stopped and key switch has been OFF for at least 90 seconds.
Page 694 7. . Turn both "T" handles (3) all the way out 11. If the precharge is greater than 172 kPa (25 (counterclockwise) before attaching charging psi), proceed to Step 13. If the precharge is less hose to accumulator gas valve. than 172 kPa (25 psi), then set the regulator (6, Figure 5-7) for 172 kPa (25 psi) at gauge (5).
Page 695 14. After charging to the correct pressure, close NOTE: If a new charging valve was installed, the valve (2). Let the pre-charge set for 15 minutes. valve stem must be seated as follows: This will allow the gas temperature and pres- a.
Page 696 ACCUMULATOR STORAGE Temperature During Precharge PROCEDURES Temperature variation can affect the precharge pres- sure of an accumulator. As the temperature increases, the pre-charge pressure increases. Con- versely, decreasing temperature will decrease the precharge pressure. In order to insure the accuracy of the accumulator precharge pressure, the tempera- ture variation must be accounted for.
Page 697 Installation 6. Stand the accumulator upright and secure. Install the pressure gauges and charge the accumulator first to 172 kPa (25 psi), then to 690 kPa (100 psi). Remove the gauges from the accumulator and install a plastic dust cap over the hydraulic port assembly.
Page 698 FLOW AMPLIFIER FIGURE 5-8. FLOW AMPLIFIER VALVE 1. Cap Screw Removal 2. Lockwasher 3. Cap Screws 4. Lockwasher 5. Cover 6. O-Ring 7. O-Ring 8. O-Ring Relieve pressure before disconnecting hydraulic 9. Not Used and other lines. Tighten all connections before 10.
Page 699 FIGURE 5-8 FLOW AMPLIFIER VALVE L05035 Steering Component Repair L5-15...
Page 700 Disassembly NOTE: The flow amplifier valve is a precision unit manufactured close tolerances, therefore complete cleanliness is a must when handling the flow amplifier valve. Work in a clean area and use lint free wiping materials or dry compressed air. Use a wire brush to remove foreign material and debris from around the exterior of the valve before disassembly.
Page 701 Reassembly 1. Thoroughly lubricate each part prior to installa- tion using clean, type C-4 hydraulic oil. 2. Reassemble the Amplifier spool assembly in reverse order. Refer to steps 12 & 13, and Fig- ure 5-10 under disassembly. 3. Install orifice screw (13, Figure 5-8). Tighten ori- fice screw to 0.5 N·m (4 in.
Page 702 STEERING CONTROL UNIT Spline Inspection Whenever the steering control unit is removed for Removal service, the steering column shaft should be inspected for excessive wear. 1. Thoroughly clean splines on steering column shaft and inspect for damage or excessive Relieve pressure before disconnecting hydraulic wear.
Page 703 Installation Disassembly 1. Lubricate splines of steering column shaft with a molybdenum disulphide or multi-purpose NLGI grease. 2. Move steering control unit into position and align with steering column shaft splines. Secure The steering control unit is a precision unit the steering control unit in place using four cap manufactured close...
Page 704 4. Remove end cover (4) and O-ring (2, Figure 5- 10. Remove O-ring (5), kin ring (6) and bearing 13). assembly (7). 5. Remove outer gear of gear wheel set (1) and 11. Remove ring (8) and pin (9) and carefully push O-ring between gear set and distribution plate.
Page 705 Assembly 1. To install the neutral position springs, place a screwdriver in the spool slot as shown in Figure NOTE: When assembling the spool and sleeve, only 5-16. one of the two possible matching positions of the 2. Place one flat neutral position spring on each spring slots can be used.
Page 706 6. With neutral position springs (7, Figure 5-17) 8. Position the O-ring and kin ring on the spool. centered in spool and sleeve, install ring (3), 9. Position the steering unit with the housing hori- rear bearing race (4), thrust bearing (5) and zontal.
Page 707 FIGURE 5-19. 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 708 10. Install the check ball in the hole shown in Figure 11. Grease the housing O-ring (3) with Vaseline 5-20. Install threaded bushing and lightly and install in the housing groove. tighten. 12. Install the distribution plate (15, Figure 5-19) with plate holes matching the corresponding holes in the housing.
Page 709 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 proce- 4. Install new piston seal (4) and bearing (3) on dure, refer to Section G. piston (5).
Page 710 STEERING CIRCUIT FILTER The brake and steering circuit filter (Figure 5-22) 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 711 Removal Indicator Switch 1. Turn the key switch OFF, allow at least 90 sec- The indicator switch (1, Figure 5-22) is factory preset onds for the accumulators to bleed down. to actuate at 241 kPad (35 psid). When activated, the switch will illuminate the amber Hydraulic Oil Filter 2.
Page 712 STEERING AND BRAKE PUMP NOTE: If oil in the hydraulic tank has not been contaminated, the shut-off valve (6, Figure 5-23) Removal between the tank and steering pump can be closed, NOTE: Clean the steering pump and surrounding eliminating the need to completely drain the tank. area carefully to help avoid contamination of 2.
Page 713 2. Make sure the steering pump spline coupler is in place (inside hoist pump) prior to steering pump installation. NOTE: Use only Komatsu filter elements, or elements that meet the Komatsu hydraulic filtration The steering pump weighs approximately 113 specification of Beta 12 = 200.
Page 714 16. Start the truck engine and operate at low idle for Disassembly one (1) to two (2) minutes. When disassembling or assembling unit, choose a work area where no traces of dust, sand or Do not allow the engine to run with the needle other abrasive particles which could damage the valves in the open position for longer than this unit are in the air.
Page 715 7. For handling purposes, insert a 1/4"-20UNC 14. When all sleeve seals (5, 6, & 7) are clear of the cap screw into the threaded end of the control valve plate, re-extend control piston (11). While link pin (16). tipping the assembly enough to clear the hole, pull the assembly from the valve plate.
Page 716 INSPECTION 21. Piston/shoe assemblies (13) can be removed individually or as a group by pulling upward on shoe retainer (27). 22. Remove fulcrum ball (12). 23. If shoe retainer springs (28) are removed, mark which spring came from which bore as they Always wear safety goggles when using solvents must be returned to that individual bore on or compressed air.
Page 717 FIGURE 5-24. 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 718 FIGURE 5-25. 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 719 9. Piston shoes must pivot smoothly, but end play b. Measure shoe thickness (the part held must not exceed 0.076 mm (0.003 in.). between retainer (27, Figure 5-25) and cra- dle. All shoes must be equal within 0.003 10. Check end play as follows: mm (0.0001in.).
Page 720 Swashblock Group Stroke Adjuster Assembly 11. Inspect swashblock (25, Figure 5-25) for 21. Measure and record dimension “A” on stroke scratches, grooves, cracks or uneven surface. adjuster assembly as shown in Figure 5-27. Replace if defective. 22. Loosen jam nut (4). Separate stem (1) from gland (3).
Page 721 3. Press four roll pins (23) into saddle (20) until 5. Fasten control link (17, Figure 5-25) to swash- they bottom, then press saddle bearing (24) block (25) using link pin (16) and two retaining onto the pins to locate the bearing in the saddle. rings (14).
Page 722 Rotating Group Control Piston Group 16. Mating surfaces should be greased. Place cylin- 25. Install piston rings (2 & 3, Figure 5-25) into their der assembly on clean table with the valve plate respective grooves on control piston (11) using side down.
Page 723 32. Pull free end of control link (17, Figure 5-25) 40. Once assembled, remove cap screw from pin. toward back of pump housing until the open NOTE: Valve plate is a slight press fit into pump hole in the link lines up with open ports on sides housing.
Page 724 NOTES L5-40 Steering Component Repair L05035...
Page 725 SECTION L HOIST CIRCUIT INDEX HOIST CIRCUIT ..............L7-3 HOIST CIRCUIT OPERATION .
Page 726 NOTES: L7-2 Hoist Circuit L07034...
Page 727: 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 728 COMPONENT DESCRIPTION High Pressure Filters Hydraulic Tank Hoist pump output flows to two remote mounted high pressure filters located on the lower inboard side of The hydraulic tank supplies hydraulic oil for the hoist, the fuel tank. The filter elements are rated at 7 steering, and brake circuits.
Page 729 Hoist Valve The spool section of the hoist valve consists of the following components: The hoist valve (Figure 7-3) is mounted above the hoist and steering pump. Hydraulic oil from the high • Two pilot ports pressure filters is routed to the hoist valve. The hoist •...
Page 730: Hoist Pilot Valve
When there is flow through a pilot port to a spool, a Hoist-up Limit Solenoid positive differential pressure at the top of the spool The Hoist-up Limit Solenoid (2, Figure 7-4) is used in will overcome the bottom spring bias causing the the hydraulic circuit to prevent maximum hoist cylin- spool to shift to connect the high pressure core to the der extension.
Page 731: Counterbalance Valve Manifold
Counterbalance Valve Manifold There are 2 pilot pressures that can open it (cylinder head raise pressure & rod return pressure. If there is The counterbalance valve manifold (12, Figure 7-2) no raise pressure, it will take 20684 kPa (3000 psi) of is mounted at the rear of the pump/hoist valve mod- rod end return pressure to open it.
Page 732: Hoist System Operation Modes
HOIST SYSTEM OPERATION MODES The following pages describe hoist circuit operation FIGURE 7-6. HOIST CIRCUIT: FLOAT POSITION in the float, power up, hold, and power down posi- tions. (Refer to Figures 7-6 through 7-10.) 1. Hoist Relief Valve 17237 kPa (2500 psi) 2.
Page 733 FIGURE 7-6. FLOAT POSITION L07034 Hoist Circuit L7-9...
Page 734: Power Up Operation (Figure 7-7)
Power Up Operation (Figure 7-7) If the pressure exceeds 20684 kPa (3000 psi) at port The Hoist Pilot Valve spool is moved to the Power Up 23, the counterbalance valve will open again to direct position when the operator moves the lever in the oil back to the hoist valve, preventing damage to the cab.
Page 735 FIGURE 7-7. POWER UP L07034 Hoist Circuit L7-11...
Page 736: Hold Operation (Figure 7-8)
Hold Operation (Figure 7-8) FIGURE 7-8. HOIST CIRCUIT: HOLD POSITION The Pilot Valve spool is positioned to allow the pilot supply oil entering Port 12 to return to the tank 1. Hoist Relief Valve 17237 kPa (2500 psi) through Port 10. Pilot supply pressure in Ports 12 2.
Page 737 FIGURE 7-8. HOLD POSITION L07034 Hoist Circuit L7-13...
Page 738: Power Down Operation (Figure 7-9)
Power Down Operation (Figure 7-9) When the operator moves the lever to lower the FIGURE 7-9. HOIST CIRCUIT: POWER DOWN body, the Hoist Pilot Valve is positioned to direct the POSITION pilot supply oil in Ports 12 to Port 15 on the Hoist Valve to the top of the Rod End Spool 7.
Page 739 FIGURE 7-9. POWER DOWN L07034 Hoist Circuit L7-15...
Page 740: Float Operation (Figure 7-10)
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 17237 kPa (2500 psi) travels down, The Hoist Pilot Valve spool returns to 2. Flow Control Valve the FLOAT position.
Page 741 FIGURE 7-10. FLOAT POSITION L07034 Hoist Circuit L7-17...
Page 742 NOTES: L7-18 Hoist Circuit L07034...
Page 743 SECTION L HOIST CIRCUIT COMPONENT REPAIR INDEX HOIST CIRCUIT COMPONENT REPAIR ..........L8-3 HOIST VALVE .
Page 744 ASSEMBLY OF QUILL AND CYLINDER ......... . L8-19 Quill Installation .
Page 745 HOIST CIRCUIT COMPONENT REPAIR HOIST VALVE Removal 1. Shift directional control lever to PARK. Turn key switch OFF to stop engine. 2. Thoroughly clean the exterior of the hoist valve. 3. Disconnect and cap or plug all line connections to help prevent hydraulic oil contamination, Relieve pressure before disconnecting hydraulic refer to Figure 8-1.
Page 746 3. Connect pilot supply lines, tighten fittings To replace the O-rings between the valve sections: securely. 1. Match mark each part on the hoist valve to aid 4. Start the engine. Raise and lower body to check in reassembly. Remove the four tie rod nuts for proper operation.
Page 747 NOTE: Inlet section shown removed from main valve body for clarity. 3. Remove cap screws (1) and cover (2). Remove springs (3 & 5) and main relief valve (4). Remove sleeve (6), low pressure relief (7) and O-rings (8). The main relief valve (4) is factory preset at 17237 kPa (2500 psi).
Page 748 Cleaning and Inspection Assembly 1. Discard all O-rings and backup rings. Clean all 1. Coat all parts including housing bores with parts in solvent and dry with compressed air. clean type C-4 hydraulic oil. Lubricate O-rings lightly with a multipurpose grease. 2.
Page 749 5. Remove spool assembly (2, Figure 8-9). Note the color of the lower spring (blue) to insure proper location during reassembly. Also note the “V” groove (1) on end of spool. FIGURE 8-7. POPPET & BALL 1. Poppet 3. O-Ring 2.
Page 750 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 751 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 hous- ing and install cover (16).
Page 752 HOIST PILOT VALVE Installation 1. Place the hoist pilot valve into position on the Removal mounting bracket. Secure valve in place with 1. Place the hoist control lever in the body down cap screws (10, Figure 8-11). position. Make sure the body is in the full down 2.
Page 753 Disassembly 1. Thoroughly clean the exterior of the valve. Place the valve in a clean work area for disas- sembly. 2. Remove machine screw (15, Figure 8-12) seal plate (16), wiper (13) and O-ring (12). 3. Remove snap ring (1, figure 8-12), cap screws (6), cap (24), spacer (23), and detent sleeve (22).
Page 754 7. Remove relief valve (2, Figure 8-13) from the Cleaning and Inspection spool housing (1). 1. Clean all parts including housings in solvent 8. Match mark the inlet and outlet housings in rela- and blow dry with compressed air. tionship to the spool housing to insure correct 2.
Page 755 Assembly 8. Apply grease to the cross holes of the detent pin (3) to hold balls (21) and (2). 1. Thoroughly coat all parts including housing 9. Slide detent sleeve (22) into cap (24) and place bores with clean type C-4 hydraulic oil. over a punch.
Page 756 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 for O-ring replacement. Should the solenoid valve The hoist cylinder weighs approximately 1000 malfunction, replace as a unit.
Page 757 6. Install a retaining strap or chain to prevent the 5. Install new O-rings in grooves on hose flange cylinder from extending during handling. connections and lubricate with clean hydraulic oil. Position flanges over hoist cylinder ports 7. At the lower mount, straighten drive lock plate and install flange clamps.
Page 758 Disassembly 10. Insert a 13 mm (0.50 in.) dia. x 1320 mm (52 in.) threaded rod through the top and through the 1. If removal of the hoist cylinder eye bearings is hole in the disc. Thread a nut on the bottom end necessary, remove retainer ring (4, Figure 8-17) of the threaded rod below the disc.
Page 759 FIGURE 8-18. HOIST CYLINDER L08038 Hoist Circuit Component Repair L8-17...
Page 760 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 761 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 762 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 763 Assembly of Cylinder 10. Thread two guide bolts 100 mm (4 in.) long in the end of the rod (1). Install seal (8) on the end 1. Install seals (15, Figure 8-18) and bearing (14) of the rod. on second stage cylinder. Install bearings (19) and buffer seal (18), rod seal (20) and rod wiper 11.
Page 764 13. Use Loctite “LOCQUIC” Primer “T” (TL8753, or * Note: If “LOCQUIC” primer “T” (TL8753) was not equivalent), to spray mating threads on cap used, the cure time will require 24 hours instead of 2 screws and threads in rod. Allow primer to dry 3 hours.
Page 765 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 766 “disabled” truck to dump the load. In the example below, Figure 8-23 illustrates a typical hookup from the good truck. The disabled truck may be another Model 830E, or a different Komatsu model. Hookup Be certain there is an adequate, clear area to dump the loaded box.
Page 767 4. Start the engine on the good truck, place the Lowering the Body: hoist control in the power down position and 6. Place the hoist lever of the good truck in FLOAT increase engine RPM to high idle to dump the to lower the body.
Page 768 NOTES: L8-26 Hoist Circuit Component Repair L08038...
Page 769 SECTION L HYDRAULIC CHECKOUT PROCEDURE INDEX HYDRAULIC CHECKOUT PROCEDURE ..........L10-3 STEERING AND BRAKE PUMP .
Page 770 NOTES: L10-2 Hydraulic Check-out Procedure L10028...
Page 771 HYDRAULIC CHECKOUT PROCEDURE STEERING AND BRAKE PUMP 3. Install a calibrated 35,000 kPa (5000 psi) gauge on the diagnostic coupling on the steering pump Pressure Check And Adjustment Procedure test port marked “GPA” (5, Figure 10-1), located on the same side of the pump as the suction NOTE: If steering and brake pump has just been port.
Page 772 To Bleed Air From Pump: b. Bottom out the unloader valve adjustment screw (11, Figure 10-1). a. With the engine OFF and the hydraulic oil level in the tank is at the proper level, open c. Back out the pressure compensator adjust- shut-off valve in steering pump suction line.
Page 773 SHOCK & SUCTION VALVES Steering Pump Leakage Check To check for worn piston pump, measurement of the Shock & Suction Valve Settings leakage can be made from the case drain while the pump is under pressure. 1. Disconnect steering pump drain line from the hydraulic tank and securely plug port in hydrau- lic tank with a steel cap.
Page 774 b. Gently bottom out the steering relief valve NOTE: The shock & suction valves are only serviced using a 5 mm metric allen wrench. Refer to as complete units, and cannot be adjusted while Figure 10-3 for relief valve location. installed in the flow amplifier valve.
Page 775 LEAKAGE TESTS e. Measure leakage from the flow amplifier return hose (from the “HT” port). Maximum allowable leakage is 820 m (l50 in. ) per minute. If leakage is excessive, replace flow amplifier. Relieve pressure before disconnecting hydraulic lines. Tighten all connections securely before f.
Page 776 5. Remove vacuum on the hydraulic tank. Start the engine. Allow the accumulator to fill up. Mea- sure leakage from the return hose fitting on the bleeddown manifold. Maximum allowable leak- age from the bleeddown manifold is 541 ml (33.0 in. ) per minute.
Page 777 ACCUMULATOR BLEED DOWN LOW STEERING PRESSURE SWITCH PROCEDURE 1. Shut down engine and turn key switch OFF. Wait 90 seconds for steering accumulator to To safely relieve hydraulic pressure in the accumula- tors while performing leakage tests, follow these bleed down. Turn steering wheel to be sure no pressure remains.
Page 778 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. steering or loss of pressure lower than specified. power assist Worn or malfunctioning pump. Replace pump.
Page 779 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 780 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 781 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 782 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 783 FIGURE 10-5. FLOW AMPLIFIER VALVE L10028 Hydraulic Check-out Procedure L10-15...
Page 784 CHECKING HOIST SYSTEM PRESSURES NOTE: If relief valve or hoist valve assembly has 4. With engine at low-idle, place hoist lever in been replaced or rebuilt, hoist relief valve pressure power up position and hold until body is in the should be checked.
Page 785 NOTE: Each 1/4 turn of the adjustment screw will 3. If power down relief pressure is not within spec- cause approximately 1,034 kPa (150 psi) change in ifications, remove cap and adjust relief valve (2, pressure. Figure 10-7) on hoist pilot valve (1). e.
Page 786 HOIST COUNTERBALANCE VALVE 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” port. following procedures labelled...
Page 787 1.) If pressure is still below 20 684 kPa (3000 Counterbalance Valve Adjustment psi), continue increasing engine speed in 1. Loosen locknut on adjustment stem of counter- steps of 300 rpm, while in third stage and balance valve (4, Figure 10-9) on manifold. observing pressure gauge.
Page 788 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 789 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 790 HYDRAULIC SYSTEM FLUSHING PROCEDURE The following instructions outline the procedure for 10. To be able to fully extend the hoist cylinders in flushing the hydraulic system: the following procedure, disconnect hoist limit solenoid in brake cabinet behind cab. 1. Shut down engine and turn key switch OFF. Allow at least 90 seconds for the accumulator to 11.
Page 791 OIL CLEANLINESS CHECK 15. Increase engine speed to full throttle and per- form the following: To check the hydraulic system for contaminants or a. Hoist up to full extension, hold for 10 sec- debris, a high quality particle counter is required. onds, then allow cylinders to float down.
Page 792 NOTES: L10-24 Hydraulic Check-out Procedure L10028...
Page 793: Options And Special Tools
SECTION M OPTIONS AND SPECIAL TOOLS INDEX ANSUL FIRE CONTROL SYSTEM (M02005)..........M2-1 ENGINE COOLANT HEATER (M07011) .
Page 794 NOTES: M1-2 Index M01055...
Page 795 SECTION M2 FIRE CONTROL SYSTEMS INDEX FIRE CONTROL SYSTEM (MANUAL) ..........M2-3 Operation .
Page 796 NOTES M2-2 Fire Control Systems M02005...
Page 797 FIRE CONTROL SYSTEM (MANUAL) The fire control system aids in protecting the Operation machine in the event of a fire. The system consists To actuate the fire control system, pull the safety ring on either of the actuators and depress the lever. One •...
Page 798 3. Remove each extinguisher from its bracket. 4. Disassemble bursting disc union and replace the ruptured bursting disc with flat side toward extinguisher. 5. Fill tank with dry chemical to not more than three inches (76 mm) from the bottom of the fill opening.
Page 799 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1 The Checkfire Electric Detection and Actuation Sys- tem - Series 1 (Figure 2-5) uses linear detection wire. This is a two conductor heat rated thermo cable. When the detection cable is subjected to 221°F (105°C) the insulating coating of the cable melts allowing the conductors to short together clos- ing the electric circuit to the squib which detonates...
Page 800 Actuator (Figure 2-6) Provides automatic and manual means of fire sup- pression system actuation. By pulling the ring pin under the knob and then depressing the red knob, the puncture pin will rupture the diaphragm in the actuator and apply the system. Automatically, the squib is fixed to rupture the cartridge disc when the linear detection wire is exposed to temperatures in excess of its rated range.
Page 801 Securing the Detection Wire be on. This indicates the power wire is installed correctly to the control module. If After the linear detection wire has been loosely light does not appear, check all connections installed, secure it to the equipment being protected to insure they are snapped together.
Page 802 c. Proceed to the end of the last length of detection wire and remove the jumper assembly (Figure 2-15). Finally, put original plugged blank connector onto detection wire. The test module light should immediately go out. If light does not go out refer to "Trouble- shooting".
Page 803 Installation Procedure for Squib Using wrench, insert squib into upper right inlet hole on actuator body and firmly tighten (Figure 2-18). After all testing has been completed and all test kit components removed, proceed to arm the system. After installing squib into actuator body, loosen pro- tective shipping cap from squib and remove bridge (Figure 2-19).
Page 804 INSPECTION AND MAINTENANCE 4. Weigh the actuation cartridge on the electric detection and actuation system. Replace car- SCHEDULES tridge if the weight is 1/4 oz. (7 g) less than that stamped on cartridge. Check the cartridge threads for nicks, burrs, cross threading and rough on feathered edges.
Page 805 10. Remove the test kit from the system by discon- necting the squib connector from the test mod- ule (Figure 2-24). Failure to remove jumper assembly will cause system discharge when squib is installed into electric detection and actuation system. 11.
Page 806 What to Expect When a fire suppression system discharges, there is some noise, accompanied by clouds of dry chemical. While breathing foreign particles is not pleasant, the agent is non-toxic. What to Do After the Fire is Out The machinery should not be restarted until it has been serviced and cleaned (water spray or steam may be used to remove the dry chemical).
Page 807 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM TROUBLE: Green Indicator Light on Control Module Does Not Go On When Button is Depressed. POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Blown fuse in battery connector assembly Look for possible short in external power wiring and change fuse Battery connection loose Clean and tighten...
Page 808 NOTES M2-14 Fire Control Systems M02005...
Page 809 SECTION M ENGINE COOLANT HEATER INDEX ENGINE COOLANT HEATER ............M7-3 GENERAL .
Page 810 NOTES: M7-2 Engine Coolant Heater M07012...
Page 811 ENGINE COOLANT HEATER GENERAL HEATING ELEMENT To aid in cold weather starting, the truck can be Removal equipped with cooling system heaters. Two high 1. Disconnect the external power source at the capacity coolant heating units are mounted under the plug-in receptacle.
Page 812 Installation 1. Install new heating element. a. Cover the new heating element threads with an anti-seize thread compound. 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.
Page 813 SPECIAL TOOLS NITROGEN CHARGING VALVE Part Number Description EB1759 Nitrogen Suspension & Charging Kit Accumulator Nitrogen Charg- 1. “T” Handle Valve 2. Charging Valve Adapter 3. Manifold Outlet Valves (from gauge) 4. Inlet Valve (from regulator) 5. Regulator Valve (Nitrogen Pressure) 6.
Page 814 OFFSET WRENCH Part Number Description TZ3535 Offset Box End Miscellaneous & Wrench, Cab Mounting 1.5 in. TORQUE ADAPTER Part Number Description TZ2734 3/4 in. Torque Miscellaneous Adapter HANDLE Part Number Description TZ2733 Tubular Handle Use with PB8326 & TZ2734 SEAL INSTALLER Part Number Description TY2150...
Page 815 SLEEVE ALIGNMENT TOOLS Part Number Description TZ0992 Sleeve Rear Suspension Alignment and Anti-sway Bar Tool TY4576 Sleeve Steering Linkage Alignment and Tie Rod Tool Assembly, Refer to Section “G” QUICK DISCONNECT COUPLING Part Number Description PB6039 Hydraulic Miscellaneous Coupling HARNESS Part Number Description EF9160...
Page 816 BELT TENSION TESTER Part Number Description PC2061 Belt Tension A/C Belt Tester Tension Check BELT ALIGNMENT TOOL Part Number Description EL8868 V-Belt A/C Belt Alignment Tool Alignment SOCKETS AND ADAPTERS Part Description Number TZ2726 Socket 1-1/8” Miscellaneous TZ2729 Socket 1-1/4” Miscellaneous TV7567 Socket 1-5/16”...
Page 817 MISCELLANEOUS SERVICE TOOLS The tools in the following table can be ordered from The following table lists more special tools that will be necessary for various service procedures: Kent-Moore: Part Description Part Number Description Number J-24092 Puller Legs A/C Service EJ2847 Pin Removal Tool Rear Suspension...
Page 818 Puller Tool suspension piston KC7095 Pusher Cap Screws, 1.25 x 8 in. Use on 830E-AC WA0366 Hardened Flatwashers, 1.25 in. Refer to Section G, Drive Axle, Spindles, and Wheels, for information on using the spindle tool to properly remove the spindles from the machine.
Page 819 SECTION M RADIATOR SHUTTERS INDEX RADIATOR SHUTTERS 3 OPERATION ............. . . M19-3 Hydraulic Circuit .
Page 820 NOTES: M19-2 Radiator Shutters M19003...
Page 821 RADIATOR SHUTTERS The optional radiator shutters aid in maintaining proper OPERATION 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 822 Electrical Circuit: A switch is located in a box (2, Figure 19-2) attached to the right upright structure beside the automatic lubrica- tion system grease reservoir (4) that may be used to disable the shutters during warm weather. The shutters are normally activated by the engine ECM.
Page 823 5. Wiring Harness 8. To Cylinder Head End 3. Pressure Reducing Valve 6. Tee Fitting 9. To Cylinder Rod End TABLE I. Komatsu SSDA16V160 Engines Coolant Temperature Intake Manifold Temperature Fuel Temperature Open 88 C (190 F) Open 60 C (140 F)
Page 824 TABLE II. Troubleshooting 1. Testing operation of shutters With engine at slow idle, connect a Shutters close - GO TO STEP 11 24 VDC power source to solenoid Shutters stay open - GO TO STEP valve (5, Figure 19-1) 2. Check hydraulic pressure to Install tee fittings (6, Figure 19-3) in In Spec - GO TO STEP 3 cylinder rod end...
Page 825 TABLE II. Troubleshooting 11. Check for proper voltage on With the key switch ON, use a In Spec - GO TO STEP 13 Relay Board 8 V.O.M. to check for 24 VDC in cir- Out of Spec - GO TO STEP 12 cuit 712R at relay K3.
Page 826 Hydraulic Troubleshooting Cause Remedy Go to 11 Electri- electrical cal prob- trouble- shooting With engine at 11 Electri- Go to YES-3Connect 24 slow idle, con- cal prob- electrical VDC power source nect a 24 VDC to solenoid valve. trouble- power source There should be shooting NO CHANGES FROM...
Page 827 Hydraulic Troubleshooting (Continued) Cause Remedy Pressure Replace reducing pressure valve (2) reducing is defec- valve (2) Install tee fitting between tive oil supply hose (1) and pressure reducing valve (2). Connect pressure gauge with a 0-35,000 kPa (0-5000 psi) range to tee fitting.
Page 828 Electrical Troubleshooting Connect a 24VDC supply to terminal 65S on Relay Board 8, relay 5. • (This signals the shutters to close by bypassing the engine ECM signal.) Be certain the A/C system is turned OFF, or disconnect wire 65T at relay 3. •...
Page 829 SECTION M20 PAYLOAD METER III ™ INDEX OPERATION SECTION ............M20-5 Introduction .
Page 830 Setting the Komatsu Distributor ........
Page 831 Setting the Komatsu Customer ........
Page 832 Calibration Problems ............M20-41 Alarm 1 - Left Front Pressure High .
Page 833 OPERATION SECTION INTRODUCTION Data Gathering Windows 95/98/NT software is available to down- Payload Meter III (PLMIII) measures, displays and load, store and view payload and fault information. records the weight of material being carried by an off- The PC software will download an entire truck fleet highway truck.
Page 834 COMPONENT DESCRIPTION System Diagram Suspension Pressure Sensors Operator Display PLMIII uses a two-wire pressure sensor. The range The speedometer/display gauge is used as a speed- ometer and payload display. The top display is used for the pressure sensor is 4000 psi (281 kg/cm ) and for speed and can display metric (km/h) or English the overload limit is 10,000 psi (700 kg/cm...
Page 835 3-wire hardware connection. Connections to the truck was loaded using a continuous loader and this serial port need to be approved by Komatsu. flag the haul cycle record. All other functions will be Several protocol options are available and detailed normal regardless of brake lock usage.
Page 836 Key Switch Input Load Lights PLMIII monitors the status of the key switch. 24vdc PLMIII uses load lights to indicate to the shovel oper- indicates that the key switch is on, open indicates the ator the approximate weight of the material in the key switch is off.
Page 837 Wiring and Termination Most of the PLMIII truck connections use a heavy- duty cable. This yellow multi-conductor cable uses a 16awg, finely stranded wire designed for continuous motion operations. The conductors are protected by a foil and braided shield for electronic noise immunity and physical strength.
Page 838 OPERATOR’S DISPLAY AND SWITCH Using the Operator ID The current operator ID number is recorded with Reading the Speedometer each haul cycle. The number can be between 0 and The top window of the speedometer/display gauge is 9999. the speedometer section. The display shows the To set the Operator ID: speed indicated by the frequency being received by the gauge.
Page 839 Total Load Counter The inclinometer displays whole degrees of incline. Positive incline is truck nose up. The gauge will The total load counter records the number of loads quickly display the type of information shown every hauled since the last time it was cleared. This display 10 seconds.
Page 840 PAYLOAD OPERATION & CALCULATION rated load for 10 seconds without the brake lock applied, the meter will switch to loading and record Description of Haul Cycle States the continuous_loading flag in the haul cycle. The typical haul cycle can be broken down into eight The payload meter switches from loading to maneu- distinct stages or states.
Page 841 SOURCES FOR PAYLOAD ERROR Load Calculation The final load calculation is different from the last Payload Error swingload calculation. The accuracy of the swing The number one source of error in payload calcula- load calculation depends on loading conditions and tion is improperly serviced suspensions.
Page 842 HAUL CYCLE DATA Loading Conditions The final load calculation of the PLMIII system is not PLMIII records and stores data in its on-board flash sensitive to loading conditions. The final load is cal- memory. This memory does not require a separate culated as the truck travels away from the shovel.
Page 843 Haul Cycle Data The following information is recorded for each haul cycle: Table 1: HAUL CYCLE DATA Data Unit Remark Truck # alpha- Up to 22 characters can be stored in this field to identify the truck. Typically this field will be just the numeric truck number.
Page 844 Haul Cycle Warning Flags F: Final Zone to Dumping Transition The payload meter expects haul cycles to progress in This message is generated when the payload meter a particular way. When something unexpected takes senses a body-up while it is calculating the final pay- place, the system records a warning flag.
Page 845 M: Haul Cycle Too Long Sprung Weight Data The haul_cycle_too_long flag indicates that the haul The payload meter is constantly monitoring the live cycle took longer than 18.2 hours to complete. The payload calculation. This value naturally rises and times stored for particular events may not be accu- falls for a loaded truck depending on road and driving rate.
Page 846 Fault Code Data Table 2: Fault Code Name Description Left front pressure high Input current > 22 ma Left front pressure low Input current < 2 ma Right front pressure high Input current > 22 ma Right front pressure low Input current <...
Page 847 PC SOFTWARE OVERVIEW Installing the PLMIII Software The CD ROM containing the Payload Data Manage- PC Overview ment (PDM) Software will automatically begin instal- The PC software has several basic functions: lation when it is inserted into the drive on the PC. If this does not happen, the software can be installed •...
Page 848 DOWNLOADING DATA To download the payload meter: PLMIII records many types of data. The PLMIII PC software is designed to download the data from a 1. Connect to the payload meter and start the PC whole truck fleet. Instead of creating one data file for software.
Page 849 PLM III SYSTEM CONFIGURATION Short Tons: Payload is displayed in short tons, dis- tances and speeds will be displayed in Miles Starting Communications Metric Tons: Payload is displayed in metric tons, dis- The PDM software allows users to download and tances and speeds are displayed in Kilometers configure the system.
Page 850 There are also many configuration and download Setting the Date and Time options available from this screen. The Connection Menu is updated only when the connection is first made. It does not update automatically. To view changes made while connected, the user must close the window and reconnect to the payload meter.
Page 851 This field in the haul cycle record can hold the name changed from metric to short tons or long tons using of the Komatsu distributor that helped install the sys- the Truck Configuration screen. This selection also tem. Komatsu also assigns a distributor number to...
Page 852 Clean Truck Tare Inclinometer Calibration The payload meter uses the clean truck tare value to The inclinometer calibration procedure is designed to calculate carry-back load for each haul cycle. The compensate for variations in the mounting attitude of carry-back stored in the haul cycle record is the new the inclinometer.
Page 853 The truck type is the size of the truck from the family to view and for what dates and times. of Komatsu trucks. This allows the user to quickly The query items are added in the "AND" condition. If view results from different types of trucks on the the user selects a truck # and date range, the query property.
Page 854 Sorting on Date Range 2. Change the “From” date to January 5, 2000. The default query starts in 1995 and runs through the current date on the PC. To narrow the range to a spe- cific date, change the “From” and “To” dates. For example, to view the haul cycle reports from truck 374 for the month of July, 2000: 1.
Page 855 Creating Reports Reports can be generated and viewed on the screen Date Time or printed. These reports are generated from the Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000 0:00 query displayed on the Payload Summary Screen. From the example in "Sorting on Time Range", the report printed would only contain data from truck 374 6:00...
Page 856 NOTE: Some haul cycles may contain the Sensor Input warning flag. This indicates that one of the four pressure sensors or inclinometer was not functioning properly during the haul cycle. Haul cycles with this warning are displayed in red on the Payload Summary window and are not included in the summary statistics for reports or display.
Page 857 Creating Graphs Exporting Data The PLMIII software can generate graphs that quickly summarize payload data. These graphs can be customized for printing. Just like the reports, the graphs are generated from the query displayed on the “Payload Summary” screen. From the "Sorting on Time Range"...
Page 858 • Reserved 1-5, 7-10: These values are internal calculations used in the continued development of PLMIII and should be ignored. • Reserved 6: This value is the payload estimate at the shovel just before the truck begins to move. Two sets of data are exported. At the top of the file will be the haul cycle data.
Page 859 To export data in ZIP format: Deleting Haul Cycle Records 1. Confirm that the data displayed is the query To delete haul cycle records from the main database, data that needs to be exported. press the "Delete" button at the bottom of the “Pay- load Summary”...
Page 860 Viewing Alarms Deleting Alarm Records From the Payload Summary screen, click the To delete alarm records from the main database, “Alarms” button to display the alarm screen. The press the "Delete" button at the bottom of the “Alarm alarms are sorted by the query settings from the Pay- Display”...
Page 861 TROUBLESHOOTING SECTION TROUBLESHOOTING Real-Time Data Display Troubleshooting the PLMIII system is done through the PC software you can: • View active alarms. • View the sensor inputs using the Real-Time Data Display. • Test the payload lights. • Create log files of sensor inputs for further analy- sis.
Page 862 Creating Log Files of Inputs Daily Inspections The PC software can create a text file of the live data An important part of maintaining the Payload Meter stream from the payload meter. This can be very use- III (PLMIII) system is monitoring the basic inputs to ful for diagnostic purposes.
Page 863 Abnormal Displays at Power-Up The payload meter performs several internal memory system checks every time it powers-up. In case of error, the operator gauge may display an error code when power is applied to the PLMIII system. Er:01 - Bad Truck Configuration error indicates that the meter encountered an error while reading the current truck configuration record from memory.
Page 864 No Payload Display When Key Switch is Turned ON • Confirm battery voltage in PLMIII junction box between TB45-A (positive) and TB45-X (ground). • Check the 5A circuit breaker (CB A) in PLMIII junction box. • Check all connectors and terminal connectors in the power circuits to the payload meter. •...
Page 865 No Display on Speedometer No Display on Operator Display • If the speedometer works but the operator displays remain blank, confirm payload connections at “No Payload Display When Key Switch is Turned ON”. M20008 02/05 Payload Meter III M20-37...
Page 866 No Communications With PC In a case where the laptop PC will not properly connect to the PLMIII system: • Confirm power to the payload meter. • Confirm laptop serial port setting using the PC software. From the mail menu select "Change Program Options".
Page 867 Load Lights Don’t Light During Loading • Confirm that the truck operator uses the brake lock switch (NEUTRAL) during loading. Without this input, the payload meter will not properly recognize swingloads. • Confirm bulbs in payload lights by using lamp check mode. •...
Page 868 Load Lights Remain ON Load Lights Remain ON During Dumping Display Doesn't Clear When The Load Is Dumped • Confirm the body up switch signal. When the body up signal is not properly received during dumping, the payload meter may maintain the lights after the body is lowered. •...
Page 869 Calibration Problems • Confirm that the truck is empty and clean. • Confirm that the payload meter is in the proper haul state. The payload meter must be in the empty, or tare zone states to begin calibration. This can be checked by using the real-time monitor mode of the Payload Data Manager software.
Page 870 Alarm 1 - Left Front Pressure High Alarm 2 - Left Front Pressure Low Troubleshoot Wiring to Left Front Suspension These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma. The pressure sensor is designed to output 4-20ma over a pressure range of 4000 psi.
Page 871 Alarm 3 - Right Front Pressure High Alarm 4 - Right Front Pressure Low Troubleshoot Wiring to Right Front Suspension These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma. The pressure sensor is designed to output 4-20ma over a pressure range of 4000 psi.
Page 872 Alarm 5 -Left Rear Pressure High Alarm 6 - Left Rear Pressure Low Troubleshoot Wiring to Left Rear Suspension These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma. The pressure sensor is designed to output 4-20ma over a pressure range of 4000 psi. •...
Page 873 Alarm 7 - Right Rear Pressure High Alarm 8 - Right Rear Pressure Low Troubleshoot Wiring to Right Rear Suspension These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma. The pressure sensor is designed to output 4-20ma over a pressure range of 4000 psi.
Page 874 Alarm 9 - Inclinometer High Alarm 10 - Inclinometer Low Troubleshoot Inclinometer Wiring These alarms indicate that the voltage to the payload meter from the inclinometer is out of range. The voltage on signal 39FE should be greater than 0.5v and less than 5.0v as measured in the junction box between TB46-. M20-46 Payload Meter III 02/05 M20008...
Page 875 Alarm 13 - Body Up Input Failure The payload meter senses when the load is dumped without receiving a body-up signal. When the load quickly drops below 50% without the body up signal, Alarm 13 is set. The alarm will be cleared when a normal dump cycle is detected.
Page 876 Alarm 16 - Memory Write Failure Alarm 17 - Memory Read Failure These alarms indicate that the payload meter has encountered a problem internally with its memory. It is recom- mended that power to the payload meter be removed for 1 minute. First turn the key switch OFF. Wait 30 seconds, then turn the battery disconnect OFF.
Page 877 Alarm 18 Payload meter detected an undercharged suspension condition on the rear right suspension. The suspension may be in need of servicing. Refer to Section H in the shop manual for information on charging the suspensions. Alarm 19 Payload meter detected an undercharged suspension condition on the rear left suspension. The suspension may be in need of servicing.
Page 878 Operator Switch Doesn't Work Alarm 26 - User Switch Fault - SELECT Alarm 27 - User Switch Fault - SET • Confirm power to the payload meter speedometer and display gauge. • Confirm that a laptop is not connected to the PLMIII system. •...
Page 879 Connector Map This diagram shows the general location of connectors, terminal boards and miscellaneous connections. M20008 02/05 Payload Meter III M20-51...
Page 880 Connectors M20-52 Payload Meter III 02/05 M20008...
Page 881 PLMIII CHECK OUT PROCEDURE General Description 8. Return to the cab and check the speedometer/ display gauge. The gauge will display the cur- The process consists of attaching dummy loads in rent payload. With the EJ3057 harnesses place of the suspension pressure sensors and attached at the sensor locations, the payload checking the pressures indicated by the payload should be 0.
Page 882 15. Press and hold the “SELECT” button on the NOTE: The gauge will quickly display the type of information being displayed every 1 minute. For dashboard. will be displayed. Release the example, if the left-front pressure is being displayed, button and the right-rear pressure will be dis- will quickly display every minute.
Page 883 26. Setting the Komatsu Distributor. NOTE: This field in the haul cycle record can hold the name of the Komatsu distributor that helped install the system. Komatsu also assigns a distributor • Set the time.
Page 884 29.2 kg/cm (250 psi and 416 psi) are accept- service. Komatsu also assigns a customer number to able. Record the values displayed. each customer. This number is used on all warranty 33.
Page 885 PLMIII CHECKOUT PROCEDURE 42. Remove the EJ3057 harness from the left front suspension junction box, TB42-A and TB42-B. CONFIRMATION 43. Wait at least 1 minute and remove the EJ3057 Flashburn Programming harness from the left-rear connections in the rear junction box, TB61-B and TB61-C. General Instructions: 44.
Page 886 4. Confirm the proper communications port for the programming laptop. This is usually COM 1. Flashburn Press “NEXT”. 1. Power Turn on power to the target device. This will start the programming process. Flashburn Comm Port: COM 1 2. Select 1.
Page 887 Confirmation Checklist Use the Real Time Data Screen in order to verify the checklist items in the table below. Checklist Item Value Initials PLMIII Software Version User switch and display works properly Left - Front Pressure Right - Front Pressure Left - Rear Pressure Right - Rear Pressure Inclinometer...
Page 888 NOTES PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE MANUFACTURED UNDER LICENSE F ROM L.G. HAGENBUCH holder of U.S. Patent Numbers 4,831,539 and 4,839,835 M20-60 Payload Meter III 02/05 M20008...
Page 889 SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX RESERVE ENGINE OIL SYSTEM ........... M31-3 Operation .
Page 890 NOTES M31-2 Reserve Engine Oil System M31004...
Page 891 RESERVE ENGINE OIL SYSTEM The reserve engine oil system is designed to add more oil capacity to the engine sump and to reduce frequent servicing of the engine oil. The constant cir- culation of oil between the engine sump and reserve tank (9, Figure 31-1) increases the total volume of working oil.
Page 892 Operation LED Monitor Light Engine oil is circulated between engine oil pan (1, • Steady - Pump 1 is withdrawing oil from the engine sump and bringing down the oil level. Figure 31-2) and reserve tank (2) by two electrically driven pumps (pump 1 and pump 2) within a single •...
Page 893 Tank Fill Control (Optional) With the reserve oil system the engine oil level is held constant, with only the reserve tank needing routine filling. The fill system automatically controls the filling of remote tank from a convenient ground level position. Filling of the tank to the proper “full” level is fast and accurate and accomplished in 2 to 3 minutes.
Page 894 SERVICE Every 500 Hours: 1. Change all engine and system filters, if applica- Between oil drains, the only normal servicing required is routine replenishment of oil at the reserve ble. supply tank. Maintenance of running levels should be 2. More system failures result from bad electrical checked routinely;...
Page 895 TROUBLESHOOTING NOTE: There is a condition that would show a level higher than the controlled point. If both the engine It is important to understand the LED signal for the and reserve tank are overfilled, there is no room in pumping unit.
Page 896 SYSTEM ELECTRICAL SCHEMATICS FIGURE 31-4. FILL SYSTEM SCHEMATIC 1. Fill Valve 4. Battery Disconnect Box 2. Oil Level Sensor (top 5. Ground Wire of reserve oil tank) 6. Remote Fill Control Box 3. 15 Amp Circuit Breaker M31-8 Reserve Engine Oil System M31004...
Page 897 SECTION N OPERATOR CAB INDEX TRUCK CAB ..............N2-1 CAB COMPONENTS .
Page 898 NOTES N1-2 Index N01020...
Page 899 SECTION N2 TRUCK CAB INDEX TRUCK CAB ..............N2-3 TRUCK CAB AND COMPONENTS .
Page 900 NOTES: N2-2 Truck Cab N02019...
Page 901: Truck Cab
Hydraulic components are Komatsu Distributor. located outside of the interior and are accessed through covers (2, Figure 2-1) on the front of the cab.
Page 902: Removal
Prior to cab removal or repair procedures, it may be 7. Close heater shutoff valves located at the water necessary to remove the body to provide clearance pump inlet housing on the right side of the for lifting equipment to be used. If body removal is engine and at the water manifold.
Page 903: Installation
FIGURE 3-2. CAB HYDRAULIC AND ELECTRICAL CONNECTIONS 1. Cab 4. Hoist Valve Hoses 2. Steering Control Valve 5. Electrical Harness Connectors 3. Hydraulic Components Cabinet 12. Check for any other hoses or wiring which may 2. After cab is positioned, insert the remaining cap interfere with cab removal.
Page 904: Cab Door
6. Remove caps and reinstall air conditioning sys- 5. Insert lifting sling through door and attach to tem hoses from compressor and receiver/drier. hoist. Remove cap screws (a swivel socket works best) securing door hinge to cab and lift 7. Refer to "Heater/Air Conditioning System" for door from cab.
Page 905: Door Jamb Bolt Adjustment
Door Jamb Bolt Adjustment 4. The door seal should firmly grip the paper all along the top, front, and bottom edge of the Over a period of time, the door latch mechanism and door. If the paper is loose all around, REPEAT door seals may wear and allow dirt and moisture to STEP 2.
Page 906: Door Handle Plunger Adjustment
2. Transfer the center of this opening onto the skin Door Handle Plunger Adjustment of the cab nearest where the door jamb bolt is If the door handle becomes inoperative, it can either located. Use a T-square or other measuring be adjusted or replaced.
Page 907: Replace Door Glass
Replace Door Glass NOTE: Remove panel screws across the top last. 1. Remove hair pin clip (1, Figure 2-6) and bolt (2) from the door check strap closes to the door. NOTE: Door glass and internal door panel will drop when door panel screws are removed. •...
Page 908 5. Before removing all door panel mounting 7. Remove 2 screws (Figure 2-8) holding the roller screws, support the panel to prevent the track to the bottom of the door glass. assembly from dropping. Remove 15 mounting screws (5). NOTE: Remove panel screws across the top last. 6.
Page 909 10. 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 2-12) at bottom of glass must clear the door frame, if still on glass.
Page 910 13. Slide the new window glass into the window 16. Reinstall window frame screws which holds it to frame glass channels. Move the glass to the top the door frame. of the frame. 14. Lift window frame, holding glass at the top of the frame, and lower the assembly into the door.
Page 911: Replace Door Window Regulator
18. Install the 2 screws removed in step 8. Be sure 22. Lift door panel, regulator and glass up to align the rubber felt insert is back in place after screw holes in the panel with holes in door installing the screws. frame.
Page 912: Replace Door Handle Or Latch Assembly
Replace Door Handle or Latch Assembly Door and Door Hinge Seal Replacement 1. The door assembly seal has only three mem- The cab doors are equipped with serviceable latch bers to it (sides and top) and is glued on the handle assemblies (inner and outer).
Page 913: Door Opening Seal Removal
Door Opening Seal Removal 1. Starting at the lower center of the door opening, pull up on one end of the seal. Seal should pull loose from the cab opening lip. Pull seal loose all the way around the opening (1, Figures 2-16 &...
Page 914: Glass Replacement
GLASS REPLACEMENT Replacement Procedure Adhesive-bonded Windows Recommended Tools/Supplies The first concern with all glass replacement is • Cold knife, pneumatic knife, or a piano wire SAFETY! Wear heavy protective gloves and cutting device, long knife. Cutout tools are safety eyeglass goggles when working with available at an auto glass supply store.
Page 915 6. Using a clean lint free cloth, apply Sika Aktiva- NOTE: Do not allow the truck to move until double tor to the black ceramic Frit surrounding the the cure time for the adhesive has passed. new window. Use a clean cloth and wipe off Otherwise, vibration or movement from a moving Sika Aktivator.
Page 916: Windshield & Rear Glass
WINDSHIELD & REAR GLASS Installation 1. If the weatherstrip material previously removed Two people are required to remove and install the windshield or rear glass. One person inside the cab, is broken, weathered, or damaged in any way, use new rubber weatherstrip material. and the other person on the outside.
Page 917 3. After the glass is in place, go around the weath- erstrip and push in on the locking lip (2, Figure 2-18 or 2-19) to secure the glass in the weather- strip. 4. If windshield was being replaced, lower wind- shield wiper arms/blades back to the glass.
Page 918 NOTES: N2-20 Truck Cab N02019...
Page 919 SECTION N3 CAB COMPONENTS INDEX CAB COMPONENTS ............. . N3-3 WINDSHIELD WIPERS .
Page 920 NOTES: N3-2 Cab Components N03025...
Page 921 CAB COMPONENTS WINDSHIELD WIPERS 3. While holding the linkage stationary, remove nut (10, Figure 3-1) and disconnect the linkage The windshield wipers are operated by a 24 volt elec- from the motor. tric motor. The wipers can be adjusted for a variable 4.
Page 922 WIPER LINKAGE Installation 1. Place wiper arm (1, Figure 3-2) into the position Removal noted during removal. Install washer (3) and nut 1. Remove the wiper arms. Refer to Wiper Arm (2). Tighten the nut to 16-20 N·m (142-177 in. Removal in this section.
Page 923 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 3-4) with a 24 volt electric pump (2). The washer is controlled by the windshield wiper switch mounted on the turn signal lever.
Page 924 OPERATOR SEAT The operator's seat provides a fully adjustable cush- ioned ride for the driver's comfort and ease of opera- tion. Adjustment The following adjustments must be made while sit- ting in the seat. 1. Headrest: Move up, down, fore, or aft by mov- ing headrest (1, Figure 3-5) to desired position.
Page 925 Seat Removal Seat Installation 1. Remove cap screws (10, Figure 3-5) and hard- 1. Mount seat assembly to seat riser. Install cap ware that secures the seat base to the riser. screws (10, Figure 3-5), lockwashers, flatwash- Remove cap screws (11) that secures tether to ers and nuts.
Page 926 NOTES: N3-8 Cab Components N03025...
Page 927 SECTION N4 OPERATOR COMFORT INDEX OPERATOR COMFORT ............N4-3 HEATER / AIR CONDITIONER .
Page 928 SYSTEM PERFORMANCE TEST ..........N4-19 SYSTEM OIL .
Page 929 OPERATOR COMFORT HEATER / AIR CONDITIONER • Turning the knob one more position clockwise directs air to the dash vents only. The heater/air conditioner assembly incorporates all the controls necessary for regulating the cab interior • Turning the knob one more position clockwise temperature;...
Page 930 COMPONENTS Relays Figures 4-2 and 4-4 illustrate both the heater system Five relays (9, Figure 4-2) control the air dampers, A/ and air conditioning system parts contained in the C compressor and the heater valve. All five relays cab mounted enclosure. Refer to Air Conditioning require 12VDC through the coil which is supplied by System in this section for additional information a 24VDC to 12VDC converter (2).
Page 931 Fan Motor And Speed Control Cab Air Filter Fan speed is controlled by inserting resistor(s) (52 & Recirculation air filter (19, Figure 4-4) and fresh air 53, Figure 4-4) in series with the supply circuit to the filter (2, Figure 4-3) in the front access panel of the blower motor to reduce voltage.
Page 932 FIGURE 4-4. HEATER/AIR CONDITIONER ASSEMBLY 1. Blower Housing 15. Grommet 29. Plate, Coil 43. Screw 2. Blower Wheel 16. Casing 30. Evaporator Core 44. Discharge Flapper 3. Cover Plate 17. Gasket 31. O-Ring 45. Door, Front 4. Venturi 18. Filter Holder 32.
Page 933 FIGURE 4-5. BASIC AIR CONDITIONING SYSTEM 1. Blower Switch 7. Evaporator 13. Magnetic Clutch 2. Thermostatic Switch 8. Expansion Valve 14. Compressor Drive Pulley 3. Battery Supply 9. Suction Line 15. Receiver-Drier 4. Circuit Breaker 10. Test Gauges & Manifold 16.
Page 934 ENVIRONMENTAL IMPACT OF AIR The general cleanliness of the system and compo- CONDITIONING nents is important. Dust or dirt collected in the con- denser, evaporator, or air filters decreases the Environmental studies have indicated a weakening of system's cooling capacity. the earth’s protective Ozone (O ) layer in the outer The compressor, condenser, evaporator units, hoses...
Page 935 Refrigeration - The Act Of Cooling Ambient air, passing through the condenser removes heat from the circulating refrigerant resulting in the • There is no process for producing cold; there is conversion of the refrigerant from gas to liquid. only heat removal. The liquid refrigerant moves on to the receiver drier •...
Page 936 AIR CONDITIONER SYSTEM Ram air condensers depend upon the vehicle move- COMPONENTS ment to force a large volume of air past the fins and tubes of the condenser. The condenser is usually Compressor (Refrigerant Pump) located in front of the radiator or on the roof of the truck.
Page 937 Expansion Block Valve The storage of the liquid refrigerant is temporary. When the liquid vaporizes into a gas it will be pulled The expansion block valve controls the amount of from the bottom of the accumulator into the compres- refrigerant entering the evaporator coil. Both inter- sor.
Page 938 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 cir- the thermostat to disengage the compressor when it cuit breaker. is not needed, such as when a defrost cycle is indi- cated in the evaporator, or when the system or The blower control is a switch which provides a...
Page 939 Trinary™ Switch • Fan Clutch - The mid-range function actuates the engine fan clutch, if installed. This switch is mounted on the receiver-drier and has • High Pressure This switch opens three functions, as implied by the name: disengages the compressor clutch if system 1.
Page 940 SYSTEM SERVICING Ensure sufficient ventilation whenever refriger- ant is being discharged from a system, keeping Servicing an air conditioning system really means in mind refrigerant is heavier than air and will fall closely monitoring refrigerant flow. For this reason, to low-lying areas. the following procedures deal extensively with the When exposed to flames or sparks, the compo- proper use, handling, care and safety factors...
Page 941 SERVICE TOOLS AND EQUIPMENT Recovery/Recycle Station Whenever refrigerant must be removed from the sys- tem, a dual purpose station as shown in Figure 4-6, Mixing different types of refrigerant will damage performs both recovery and recycle procedures equipment. Dedicate one recovery/recycle sta- which follows the new guidelines for handling used tion to each type of refrigerant processing to refrigerant.
Page 942 FIGURE 4-9. VACUUM PUMP FIGURE 4-8. R-134a SERVICE VALVE 1. System Service Port 3. Service Hose Fitting nection 2. Quick Connect Vacuum Pump The vacuum pump (Figure 4-9) is used to completely evacuate all of the refrigerant, air, and moisture from the system by deliberately lowering the pressure within the system to the point where water turns to a Service Valves...
Page 943 Manifold Gauge Set A typical manifold gauge set (Figure 4-10) 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 mani- fold and hoses are for access to the inside of an air conditioner, to remove air and moisture, and to put in, or remove, refrigerant from the system.
Page 944 Installing Manifold Gauge Set 4. Connect the two service hoses from the mani- fold to the correct service valves on the com- Before attempting to service the air conditioning sys- pressor and accumulator, as shown in Figure 4- tem, a visual inspection of both the engine and A/C 11.
Page 945 SYSTEM PERFORMANCE TEST 8. Feel the hoses and components on the low side. They should be cool to the touch. Check This test is performed to establish the condition of all connections near the expansion valve; the inlet components in the system. Observe these conditions side should be warm and the outlet side cold.
Page 946 Polyalkylene Glycol (PAG) lubricating oil. This is the only oil recommended for use in this system. The Komatsu PAG oil (p/n PC2212) is the oil that is fur- nished in the system on Komatsu trucks. The receiver-drier and accumulator must be replaced each time the system is opened.
Page 947 REFRIGERANT Recycled Refrigerant Recycled refrigerant has been extracted from a mobile air conditioning system using a recovery unit. When installing a new compressor, the compres- The refrigerant is cleaned by the recovery unit as it sor must be completely drained of its oil before passes through filters located on the unit that meet installation.
Page 948 SYSTEM LEAK TESTING If an incorrect charge is suspected, recover the refrigerant from the system, and charge the system Refrigerant leaks are probably the most common with the correct operating weight 3.4 kg (7.4 lb). This cause of air conditioning problems, resulting from is not only the recommended procedure, but it is also improper or no cooling, to major internal component the best way to ensure that the system is operating...
Page 949 RECOVERING AND RECYCLING THE Electronic Leak Detector REFRIGERANT (Refer to Figure 4-7). As the test probe is moved into an area where traces of refrigerant are present, a Draining the oil from the previous recovery cycle visual or audible announcement indicates a leak. 1.
Page 950 SYSTEM REPAIR 9. Check the system pressure after the recovery equipment stops. After five minutes, system The following service and repair procedures are not pressure should not rise above “0” gauge pres- any different than typical vehicle service work. How- sure.
Page 951 System Flushing 2. Inspect all other components such as the con- denser, evaporator, hoses and fittings. If any of If any contaminants are found in system hoses, com- these items are damaged or highly contami- ponents or oil, the entire system must be flushed. nated, replace the components.
Page 952 A/C DRIVE BELT CHECKOUT PROCEDURE This procedure must be performed each time any component in the accessory drive is serviced, such as replacing a belt or removing the compressor. In addition, a 250 hour inspection of the AC drive belt is mandatory.
Page 953 FIGURE 4-15. BELT ALIGNMENT TOOL 1. AC Compressor Pulley 2. Drive Pulley 3. Alignment Tool 346 mm (13.63 in.) FIGURE 4-16. BELT TENSION DIMENSIONS N04031 10/06 Operator Comfort N4-27...
Page 954 COMPONENT REPLACEMENT Receiver-Drier The receiver-drier can not be serviced or repaired. It Hoses and Fittings must be replaced whenever the system is opened When replacing hoses, be sure to use the same type for any service. The receiver-drier has a pressure and ID hose you removed.
Page 955 Compressor Clutch pulley bearing failure is indicated by bearing noise when the A/C system is off or the clutch is not The compressor can fail due to shaft seal leaks (no engaged. Premature bearing failure may be caused refrigerant in the system), defective valve plates, by poor alignment of the clutch and clutch drive pul- bearings, or other internal parts or problems associ- ley.
Page 956 Servicing the Compressor Clutch 1. Remove the belt guard from the front of the air conditioning compressor. * RECOMMENDED TOOLS FOR COMPRESSOR CLUTCH REMOVAL AND INSTALLATION J-9399 Thin Wall Socket **J-9403 Spanner Wrench **J-25030 Clutch Hub Holding Tool Clutch Plate and Hub Assembly J-9401 Remover J-8433...
Page 957 4. Use clutch hub holding tool (2, Figure 4-18), 5. Thread clutch plate and hub assembly remover spanner wrench (J-9403), or the equivalent to (2, Figure 4-19) into the hub of clutch assembly hold clutch hub (3) while removing the locknut. (1).
Page 958 7. Inspect the friction surface on the clutch hub Pulley Removal and the friction surface on the pulley. Scoring 8. Use retaining ring pliers (3, Figure 4-22) to on the friction surfaces is normal. DO NOT remove pulley retainer ring (2) from pulley (1). replace these components for this condition only.
Page 959 11. Tighten the center screw on the puller against 2. Ensure the pulley rotates freely. If the pulley the shaft of the compressor to remove the pul- does not rotate freely, remove the pulley and ley. check for damaged components. Replace any damaged components and reinstall the pulley.
Page 960 4. Press the clutch onto the compressor using 5. Install locknut (4, Figure 4-17) and tighten the installer (1). Continue to press the clutch plate nut until it seats. The gap should now measure until a 2 mm (0.079 in.) gap remains between 1.02 ±...
Page 961 EVACUATING THE SYSTEM 2. Open the discharge valve on the vacuum pump or remove the dust cap from the discharge out- Evacuating the complete air conditioning system is let. Turn the pump on and watch the low side required in all new system installations, and when gauge.
Page 962 4. Close both valves on the manifold gauge set. NOTE: In some cases, 45 minutes of evacuation may Turn the vacuum pump off and observe the not be sufficient to vaporize all of the moisture and gauges. The system should hold the vacuum draw it out of the system.
Page 963 CHARGING THE A/C SYSTEM 1. Charge the A/C system with 3.4 kg (7.4 lbs) of R-134a refrigerant. The proper method for charging refrigerant into a R- 134a system is to first, recover all of the refrigerant NOTE: Charging is to be performed with the engine from the system.
Page 964 TROUBLESHOOTING Preliminary Checks • Cab filters - Ensure the outside air filter and inside recirculation filter are clean and free of If the system indicates insufficient cooling, or no cool- restriction. ing, the following points should be checked before • Condenser - Check the condenser for debris and proceeding with the system diagnosis procedures.
Page 965 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 966 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 967 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 968 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 A/C system on it's coldest capillary tube (bulb) is not making proper contact setting for a few minutes.
Page 969 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 replace or tighten it and recheck system perform- components.
Page 970 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 971 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C 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, Maintenance Interval in order to circulate oil and lubricate components. COMPONENT (months) Maintenance Interval...
Page 972 NOTES: N4-46 Operator Comfort 10/06 N04031...
Page 973 SECTION N5 OPERATOR CAB CONTROLS INDEX OPERATOR CAB AND CONTROLS ..........N5-3 STEERING WHEEL AND CONTROLS .
Page 974 Engine Diagnostic Port (QUANTUM) ......... . . N5-13 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS .
Page 975 OPERATOR CAB AND CONTROLS FIGURE 5-1. CAB INTERIOR - OPERATOR VIEW 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. Retard Pedal 8. Grade/Speed Retard Chart 13.
Page 976 STEERING WHEEL AND CONTROLS Multi-Function Turn Signal Switch Steering wheel (1, Figure 5-2) can be telescoped "in" and "out" and the lilt angle can be adjusted to provide a comfortable steering wheel position for most opera- tors. Horn Button Multi-function turn signal switch (4, Figure 5-2) is Horn (2, Figure 5-2) is actuated by pushing the but- used to activate the turn signal lights, the windshield ton in the center of the steering wheel.
Page 977 STEERING COLUMN Steering Column Inspection Whenever the steering column or steering control Removal unit is removed for service, the steering column shaft 1. Shut down engine by turning the key switch splines should be inspected for excessive wear. OFF and allow at least 90 seconds for the steer- 1.
Page 978 7. Tighten four cap screws (10). Dynamic retarding is available in NEUTRAL only when truck speed is above 4.8 kph (3 mph). 8. Check for proper steering wheel rotation without binding. Be certain wheel returns to neutral after When dynamic retarding is in operation, engine rpm rotating 1/4 turn left and right.
Page 979 GRADE/SPEED RETARD CHART Throttle/Accelerator Pedal Grade/speed retard chart (8, Figure 5-1), and shown Throttle/accelerator pedal (4, Figure 5-1), and shown below, provides the recommended MAXIMUM below, is a foot-operated pedal which allows the retarding limits at various truck speeds and grades operator to control engine rpm depending on pedal depression.
Page 980 The "short term" numbers listed on the chart indicate The "short term" rating will successfully accommo- the combination of speeds and grades which the date most downhill loaded hauls. It is necessary to vehicle can safely negotiate for a short duration divide haul road grade segment length by allowable before system components reach the maximum speed to determine actual time on grade.
Page 981 OVERHEAD PANEL AND DISPLAYS Status/Warning Indicator Light Panel The items listed below are located on the overhead Panel (13, Figure 5-1) contains an array of indicator panel. Refer to Figure 5-1 for the location of each lights to provide the operator with important status item.
Page 982 CENTER CONSOLE Directional Control Lever Directional Control Lever (2, Figure 5-4) is mounted on a console to the right of the operator's seat. It is a four position switch that controls the park, forward, neutral, and reverse motion of the truck. When the directional control lever is in the center N position, it is in NEUTRAL.
Page 983 Override/Fault Reset Switch R.H. Window Control Switch Switch (3, Figure 5- Switch (6, Figure 5-4) is spring-loaded to the OFF 4) is spring-loaded position. to the OFF position. • Pushing the front of the switch raises the right When pushed side cab window.
Page 984: Operator's Cab
Retard Speed Control (RSC) Adjust Dial With RSC switch on and dial adjusted, the system will function as follows: As truck speed increases to Dial (8, Figure 5-4) allows the operator to vary the the "set" speed and throttle pedal released, dynamic downhill truck speed that the retard speed control retarding will apply.
Page 985 Data Store Button Truck Control Interface (TCI) Diagnostic Port Button (10, Figure 5-4) is for use by qualified mainte- Diagnostic port (4) is used to access diagnostic infor- nance personnel to record in memory a “snap-shot” mation for the Truck Control Interface (TCI). of the AC drive system.
Page 986 HEATER / AIR CONDITIONER Heater Vents COMPARTMENT AND CONTROLS Each heater/air conditioner vent (4, Figure 5-6) is a The heater/air conditioner compartment contains flapper type which may be opened or closed or heater/air conditioner controls (6, Figure 5-1) and rotated 360° for optimum air flow. There are four some of the heater/air conditioner components, such (three not shown) across the top of the panel, one as the blower motor assembly and heater coils.
Page 987 INSTRUMENT PANEL Control Symbols This symbol when it appears on an indicator or control identifies The operator must understand the function and oper- that this indicator or control is ation of each instrument and control. Many control NOT used. functions are identified with international symbols that the operator should learn to recognize immedi- ately.
Page 988 FIGURE 5-7. PANEL GAUGES, INDICATORS, AND CONTROLS 1. Key Switch 14. Left Turn Signal Indicator 2. Engine Stop Switch with Timer Delay 15. Water Temperature Gauge 3. Rotating Beacon (Optional) 16. Lamp Check Switch 4. Heated Mirrors (Optional) 17. Headlight/Panel Illumination Light Switch 5.
Page 989 Key Switch Operation 1. Stop the truck, and reduce engine rpm to low Key switch (1, Figure 5-7) is a three-position (OFF, idle. Place the directional control lever in PARK. RUN, START) switch. Place the rest switch in the ON position to put the drive system in REST mode of operation.
Page 990 Rotating Beacon Light Switch Wheel Brake Lock Control (Optional) Switch (6, Figure 5-7) should be Switch (3, Figure 5-7) controls used when the engine is running dur- the operation of the rotating bea- ing dumping and loading operations con light. only.
Page 991 Engine Oil Pressure Gauge Left Turn Signal Indicator Gauge (9, Figure 5-7) indicates pres- Indicator (14, Figure 5-7) illuminates to indicate that sure in the engine lubrication system the left turn signals are operating when the turn sig- in pounds per square inch (psi). nal lever on the steering column is moved downward.
Page 992 Ladder Light Switch Payload Meter Switch Ladder light switch (18, Figure 5-7) Payload meter switch (21, Figure 5- turns the ladder lights on or off. 7) is a two-way, momentary rocker Pressing the top of the rocker switch switch. The top position is the turns the lights on.
Page 993 Hydraulic Oil Temperature Gauge Hourmeter Hydraulic oil temperature gauge (23, Hourmeter (24, Figure 5-7) registers Figure 5-7) indicates oil temperature the total number of hours the engine in the hydraulic tank. There are two has been in operation. colored bands: green and red. Green indicates normal operation.
Page 994 OVERHEAD STATUS / WARNING INDICATORS FIGURE 5-8. OVERHEAD STATUS / WARNING INDICATOR Row / Indicator Indicator Color Row / Indicator Indicator Color Column Description Wire Index Column Description Wire Index Hydraulic Oil Temp. High Red-24VIM/34TL No Propel/ No Retard Red-12M/75-6P1 Low Steering Pressure Red-12F/33A Propulsion System...
Page 995 Status / Warning Indicator Light Symbols B1. Low Steering Pressure Amber indicator lights alert the operator that the indi- When the key switch is turned cated truck function requires some precaution when ON, the low steering pressure lighted. warning light will illuminate until the steering system hydraulic Red indicator lights alert the operator that the indi- pressure reaches 15 858 kPa...
Page 996 C1. Low Accumulator Pre- A2. Low Hydraulic Tank Level charge Pressure This warning light indicates the The low accumulator precharge oil level in the hydraulic tank is warning light, if illuminated, indi- below recommended level. Dam- cates low nitrogen precharge for age to hydraulic pumps may the steering accumulator(s).
Page 997 E2. Low Fuel E3. Stop Engine This amber low fuel indicator This red engine monitor warning light will illuminate when the light will illuminate if a serious usable fuel remaining in the tank engine malfunction is detected is approximately 95 liters (25 gal- in the electronic engine control lons).
Page 998 B4. Manual Backup Lights A5. No Power This amber indicator will illumi- This red “no retard/no propel” nate when the manually oper- indicator light indicates a fault ated manual backup light switch has occurred which has elimi- (19, Figure 5-7) is turned ON. nated the retarding and propul- sion capability.
Page 999 E5. Battery Charging System C6. Propel System Not Ready Failure The amber indicator light func- The red battery charging system tions during start-up much like light indicates a problem has the hour glass icon on a com- been detected in the charging puter screen.
Page 1000 (utilizing the Orb- comm controller). This data is then compiled at the Komatsu computer server. Based on this information, the servicing Komatsu distributor will suggest If 24V power is disconnected (using the battery...

Komatsu 830E-AC Shop Manual

Table of Contents

Section A3 General Safety and Operating Instructions Index

Standard Torque Charts and Conversion Tables

Section B3 Dump Body Index

Section B4 Fuel Tank Index

Section C4 Power Train Index

Section C5 Air Cleaners Index

Section C7 Fan Clutch Index

Section D14 Vhms Forms Index

Section G Tires and Rims Index

Section J2 Brake Circuit Index

Section J5 Front Brakes Index

Section L Hoist Circuit Index

Section N2 Truck Cab Index

Section P2 Lubrication and Service Index

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Table of Contents