Complete service repair manual with electrical wiring diagrams for Komatsu 980E Dump Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu 980E Dump Trucks workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM031002 – 980E-4 Dump Truck Shop Manual (SN A40003-A40051, Engine SSDA18V170).pdf
CEBM031601 – 980E-4 Dump Truck Shop Manual (SN A40052 & up, Engine 18V170).pdf
PRODUCT DETAILS:
Total Pages: 1,154 + 1,070 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
00 Index and foreword
Index
Foreword, safety and general information
01 Specification
Specification and technical data
10 Structure, function and maintenance standard
Steering circuit
Hoist circuit
Brake circuits
Electrical system, 24 volt
Electrical system, AC drive
Cab air conditioning
Reserve engine oil system
20 Standard value table
Standard service value table
30 Testing and adjusting
Steering, brake cooling and hoist hydraulic system
Brake system
Accumulators and suspensions
Interface module (IM)
KOMTRAX Plus
Payload meter IV
Komatsu Wireless Bridge (KWB)
Electrical system, AC Drive
Cab air conditioning
40 Troubleshooting
Fuse, diode and relay locations
AC drive system fault codes
Troubleshooting by failure code, Part 1
Troubleshooting by failure code, Part 2
Troubleshooting by failure code, Part 3
Troubleshooting by failure code, Part 4
Troubleshooting by failure code, Part 5
Troubleshooting by failure code, Part 6
Orbcomm
Cab air conditioning
Steering system
50 Disassembly and assembly
Service tools
Wheels, spindles and rear axle
Brake system
Steering system
Suspensions
Hoist circuit
Body and structures
Operator cab
Cab air conditioning
Power module
90 Diagrams and drawings
Hydraulic circuit diagrams
Electrical circuit diagrams
CEBM031002 – 980E-4 Dump Truck Shop Manual (SN A40003-A40051, Engine SSDA18V170)….2
00 Index and foreword….4
Index….4
Composition of shop manual….5
Table of contents….7
Foreword, safety and general information….22
Foreword….25
How to read the shop manual….26
Composition of shop manual….26
Revision and distribution….26
Symbols….27
General safety….28
Safety rules….28
Safety features….28
Fire extinguisher and first aid kit….28
Clothing and personal items….28
Leaving the operator seat….29
Mounting and dismounting….29
Fire prevention for fuel and oil….29
Precautions with high temperature fluids….30
Asbestos dust hazard prevention….30
Prevention of injury by work equipment….30
Unauthorized modification….30
Precautions when using ROPS….30
Precautions for attachments….31
Precautions for starting the truck….31
Precautions before operating the truck….31
Safety at the worksite….31
Fire prevention….32
Ventilation in enclosed areas….32
Preparing for operation….32
Mirrors, windows and lights….32
In operator cab (before starting the engine)….32
Seat Belts….32
Precautions while operating the truck….33
When starting the engine….33
General truck operation….33
Ensuring good visibility….33
Traveling….34
Traveling in reverse….34
Traveling on slopes….34
Operating on snow or ice….34
Avoid damage to dump body….34
Driving near high voltage cables….35
When dumping….35
When loading….35
Working on loose ground….35
Parking the truck….35
Towing….35
Working near batteries….36
Battery hazard prevention….36
Starting with jumper cables….37
Jump starting with receptacles….37
Precautions before performing service….38
Warning tag….38
Stopping the engine….38
Proper tools….38
Use of Tie-Off Anchor During Maintenance and Repair….38
Securing the dump body….39
Jack point locations….40
Precautions while performing service….41
Keep the truck clean….41
Attachments….41
Working under the truck….41
Rotating fan and belts….41
Adding fuel or oil….41
Use of lighting….41
Radiator coolant level….42
Precautions with the battery….42
Precautions with high pressure oil….42
Handling high pressure hoses….42
Precautions when performing maintenance near high temperature or high pressure….42
Waste materials….42
Tires….43
Inspection….43
Maintenance….43
Storage….44
Handling….45
Precautions for performing repairs….46
Engine shutdown procedure after AC drive system failure….46
Precautions for welding on the truck….47
Capacitor discharge system….48
Necessary tools….48
Warnings and cautions….49
Manual DC link capacitor discharge procedure….50
Failure of the discharge system….52
Manual discharge of capacitors….53
Short isolated capacitor terminals….55
Handling electrical equipment and hydraulic components….56
Points to remember when handling electrical equipment….56
Points to remember when handling hydraulic equipment….62
Standard tightening torques….64
Effect of special lubricants on fasteners and standard torque values….64
Suggested sources for rust preventive grease….64
SAE grade 5 and grade 8 hex head capscrew and nut assemblies….65
SAE grade 9 capscrews….66
Class 10.9 capscrews and class 10 nuts….66
Standard tightening torques for fittings….67
Conversion tables….69
Common conversion multipliers….69
Operating instructions….74
Preparing for operation….76
Walk around inspection….76
Retractable ladder system….80
Using the in-cab control panel….81
Using the ground level control box….84
Emergency operation….85
Engine start-up….86
After engine start-up….87
Pre-shift brake check….87
Operation….88
Brake test setup….89
Service brake test….89
Parking brake test….90
Retard system test….91
Emergency steering system….91
Operation….91
Pre-operation testing….91
Precautions during truck operation….92
Operating on a haul road….93
Starting on a grade with a loaded truck….94
Sudden loss of engine power or loss of drive system function….94
Fuel depletion….95
Towing….95
Special Wiring Harness….96
Towing Procedure….96
Loading the dump body….97
Overload speed limit function….98
Dumping a load….98
Raising the dump body….98
Lowering the dump body (on flat ground)….99
Lowering the dump body (over a berm or into a crusher)….100
Disabled truck dumping procedure….100
Hookup….101
Raising the body….101
Lowering the body….101
Safe parking procedure….102
Normal engine shutdown procedure….102
01 Specification….104
Specification and technical data….104
Specification drawing….106
Specifications….107
Weight table….109
Fuel, coolant and lubricants….110
Suspension cylinder oil and nitrogen specifications….111
10 Structure, functions and maintenance standard….114
Steering circuit….114
Steering circuit operation….116
Steering circuit components….120
Steering control unit….120
High pressure filter….120
Steering accumulators….120
Bleeddown manifold….121
Steering accumulator bleeddown solenoid….121
Hoist up limit solenoid….121
Quick disconnect ports….121
Flow amplifier….121
Steering/brake pump operation….122
Hoist circuit….124
Hoist circuit operation….126
Hoist circuit components….127
Hydraulic tank….127
Hoist pump….127
High pressure filters….127
Hoist valve….128
Inlet sections….128
Tank ports (front) spool section….128
Work ports (rear) spool section….129
Hoist pilot valve….129
Hoist limit solenoid….130
Pilot operated check valve….130
Overcenter manifold….130
Hoist pilot valve operation….131
Float position with body down….131
Power up operation….133
Hold operation….135
Power down operation….137
Float operation….139
Brake circuits….142
General information….144
Service brake circuit operation….145
Secondary braking….147
Automatic brake application (Auto apply)….147
Parking brake circuit operation….148
Normal operation (key switch ON, engine on)….148
Wheel brake lock circuit operation….149
Brake warning circuit operation….149
Brake assembly wear data….151
Electrical system, 24 volt….154
Battery supply system….156
Batteries….156
24VDC auxiliary battery receptacles….156
Engine shutdown switch….157
Battery disconnect switches….157
Propel lockout lever….157
System busy light….157
LED lights….157
Engine starting system with prelube….158
Prelube operation….158
Cranking operation….159
Auxiliary control cabinet components….160
24VDC to 12VDC converter….160
Interface module (IM)….160
VEC blocks….161
Light timers….161
Relays….161
Ground terminals….161
24VDC power terminals….161
Body-up switch….162
Hoist limit switch….163
Electrical system, AC drive….166
General system operation….167
System components….169
Drive system controller (DSC)….169
Diagnostic information display (DID) panel….170
DSC software functions….170
Input processing….170
State machine….170
DC link state….173
Engine control….174
Alternator field control….175
Desired DC link voltage….175
Self-load….175
Propel torque control….175
Retard torque control….176
Wheel slide control….176
Resistor grid control….176
Chopper voltage control….176
Event detection and processing….177
Power-on tests….177
Initiated tests….178
Periodic tests….178
Event restrictions….178
Event logging and storage….178
Data packs….179
Event reset….179
Abnormal conditions/overriding functions….180
Engine shutdown/Engine not running….180
Limp home mode….180
AC drive system component table….181
Electronic accelerator and retarder pedals….188
Cab air conditioning….190
General information….191
Environmental impact of air conditioning….191
Air conditioning for off-highway vehicles….191
Principles of refrigeration….192
Air conditioning….192
Refrigeration – the act of cooling….192
The refrigeration cycle….192
Air conditioning system components….194
Relays….194
Fan motor and speed control….194
Cab air filter….194
Heater core….194
Actuators….194
Compressor (refrigerant pump)….196
Service valves….196
Condenser….196
Receiver-drier….196
Expansion valve….197
Accumulator….197
Evaporator core….197
Air conditioning system electrical circuit….198
Thermostat….198
Compressor clutch….198
Trinary™ switch….199
Reserve engine oil system….202
General information….204
Operation….205
Pumping unit….205
LED monitor lights….206
Tank auto fill control….207
Filling procedure (remote fill feature)….207
Service….208
Every 10 hours (each shift)….208
Every 500 hours….208
Changing oil….208
Troubleshooting….209
Circuit fuses….209
Auto fill system electrical schematic….210
20 Standard value table….212
Standard value table….212
Standard value table for truck….214
30 Testing and adjusting….220
Steering, brake cooling and hoist hydraulic system….220
General information on system checkout….222
Hydraulic system checkout procedures….223
Required equipment….223
Bleeddown procedure….223
Preliminary steps….225
Hydraulic system flushing procedure….225
Flow amplifier adjustment….229
Steering pump unloader valve adjustment….229
Auxiliary accumulator pressure verification….230
System diagnostics….230
Hoist counterbalance valve adjustment….232
Final steps….233
Oil cleanliness check….233
Hydraulic system checkout data sheet….234
Toe-in adjustment….237
Hoist cylinder leakage test….238
Steering cylinder leakage test….238
Brake system….240
General information on system checkout….242
Brake system checkout procedures….242
Required equipment….242
Initial system setup….244
Brake lock / secondary braking checkout….244
Parking brake checkout….245
Service brake checkout….246
Low brake accumulator pressure and auto apply checkout….247
Parking brake control logic checkout….249
Brake lock control logic checkout….250
Brake system checkout data sheet….253
Brake piston leakage test….261
Brake seal pressure test….261
Oil separator seal pressure test….261
Wet disc brake bleeding procedure….262
Parking brake bleeding procedure….263
Service brake disc wear inspection….264
Parking brake disc wear inspection….265
Brake valve bench test and adjustment….266
Test setup procedure….267
Brake valve output pressure adjustment….267
Final test and adjustment….268
Dual relay valve bench test and adjustment….269
Test setup procedure….270
Relay valve output pressure adjustment….270
Accumulators and suspensions….274
Accumulator charging precautions….275
Temperature during precharge….275
Bladder accumulator charging procedure….276
Precharge maintenance….279
Bladder accumulator storage….280
Bladder storage….280
Installing a bladder accumulator from storage….280
Bladder accumulator leak testing….281
Piston accumulator charging procedure….282
Piston accumulator storage….284
Piston accumulator leak testing….284
Suspension oiling and charging procedures….285
Equipment list….286
Installing the charging kit….286
Removing the charging kit….286
Support blocks for oiling and charging dimensions….287
Front suspension oiling….287
Front suspension nitrogen charging….288
Rear suspension oiling….290
Rear suspension nitrogen charging….291
Suspension pressure test….292
Interface module (IM)….294
Interface module software….296
Flashburn program installation….296
Interface module application code installation….297
Interface module realtime data monitor software installation….297
Interface module checkout procedures….298
Necessary equipment….298
Preliminary….299
Check digital inputs to the interface module….300
Check analog inputs to the interface module….303
Check serial interfaces to the interface module….303
Check outputs from the interface module….304
CHECKOUT PROCEDURE….305
KOMTRAX Plus….310
KOMTRAX Plus software and tools….312
KOMTRAX Plus controller setup procedure….312
Preliminary steps….312
Setup procedure….312
KOMTRAX Plus initialization form….316
Precautions when replacing the KOMTRAX Plus controller….317
KOMTRAX Plus controller checkout procedure….319
Preliminary steps….319
Checkout procedure….319
Payload meter IV….322
Payload meter IV software and tools….323
Payload meter IV system configuration….323
Connecting to the payload meter IV web server….323
Configuring a static IP address….323
Payload meter IV software installation….325
Payload meter IV checkout procedure….326
PLM IV system checkout data sheet….330
Electrical system, AC drive….332
General information….333
Test equipment….333
Circuit continuity and resistance checks….333
Megger test for grounds….334
Troubleshooting for grounds….337
Low voltage power supply checks….337
Drive System Controller (DSC) card checks….338
Propulsion system software installation….339
Software installation procedure….340
DSC manual test procedures….341
Accelerator pedal, retarder pedal, and retarder lever calibration and checks….344
Set truck ID number….348
Control cabinet pressure switch check….349
Checks prior to self load engine test (loadbox)….351
Verifying DSC Software Version….351
Resetting and erasing DSC event data….352
Engine running tests….353
Battery boost circuit verification….353
Selector switch check….356
Ground detection network tests….358
Self load engine test (loadbox) procedure….363
Diagnostic information display (DID) panel….365
DID panel display selection….365
DID modes display….367
Function key F1 – DID events or faults display….368
Function key F4 – DID menu display….371
DID self load engine test (loadbox)….372
DID link capacitance test….374
DID speedometer test….375
DID view software version….377
DID view overspeed setting….379
DID view data menu….380
DID inverter cutout menu….385
DID truck configuration menu….387
Language selection….394
Viewing event and statistical data….395
Viewing the DSC event summary, trigger data, and data packs….395
Viewing the statistical data….398
Logic screens….399
Datalogger function….401
Setting up the datalogger….401
Starting the datalogger….403
Uploading data….405
Consolidated truck data save….405
USB drive….406
Cab air conditioning….408
General information….409
Service tools and equipment….410
Recovery/recycle station….410
Leak detector….410
Manifold gauge set….411
Service valves….412
Vacuum pump….412
Detecting leaks….413
System performance test….414
Checking system oil….415
System flushing….416
Installing the manifold gauge set….417
Purging air from the service hoses….417
Recovering and recycling refrigerant….418
Draining oil from previous recovery cycle….419
Recovery cycle….419
Recycling procedure….419
Evacuating the air conditioning system….420
Charging the air conditioning system….421
40 Troubleshooting….424
Fuse, diode and relay locations….424
Vehicle Electrical Center (VEC-89)….425
Vehicle Electrical Center (VEC-90)….427
Vehicle Electrical Center (VEC-91)….429
Vehicle Electrical Center (RTMR1)….431
AC drive system fault codes (DSC)….434
DID panel fault code tables….436
Troubleshooting by fault code, Part 1….460
Fault Code A001: Left front suspension pressure sensor signal high….462
Fault Code A002: Left front suspension pressure sensor signal low….463
Fault Code A003: Right front suspension pressure sensor signal high….464
Fault Code A004: Right front suspension pressure sensor signal low….465
Fault Code A005: Left rear suspension pressure sensor signal high….466
Fault Code A006: Left rear suspension pressure sensor signal low….467
Fault Code A007: Right rear suspension pressure sensor signal high….468
Fault Code A008: Right rear suspension pressure sensor signal low….469
Fault Code A009: Incline sensor signal high….470
Fault Code A010: Incline sensor signal low….471
Fault Code A011: Payload meter speed sensor signal has failed….472
Fault Code A013: Body up switch has failed….473
Fault Code A014: Payload meter checksum computation has failed….474
Fault Code A018: Right rear flat suspension cylinder warning….475
Fault Code A019: Left rear flat suspension cylinder warning….476
Fault Code A022: Carryback load excessive….477
Fault Code A101: High pressure detected across an hydraulic pump filter….478
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level….480
Fault Code A107: GE has generated a propel system caution….481
Fault Code A108: GE has generated a propel system temperature caution….482
Fault Code A109: GE has generated a propel system reduced level signal….483
Fault Code A111: Low steering pressure warning….484
Fault Code A115: Low steering precharge pressure detected….485
Fault Code A117: Low brake accumulator pressure warning….486
Fault Code A118: Brake pressure is low while in brake lock….487
Fault Code A123: GE has generated a reduced retarding caution….488
Fault Code A124: GE has generated a no propel / no retard warning….489
Fault Code A125: GE has generated a no propel warning….490
Fault Code A126: Oil level in the hydraulic tank is low….491
Fault Code A127: IM-furnished +5 volt output for sensors is low….492
Fault Code A128: IM-furnished +5 volt output for sensors is high….493
Fault Code A139: Low fuel warning….494
Troubleshooting by fault code, Part 2….498
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil….500
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil….501
Fault Code A152: Starter failure….502
Fault Code A153: Battery voltage is low with the truck in operation….503
Fault Code A154: Battery charging voltage is excessive….504
Fault Code A155: Battery charging voltage is low….505
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level….506
Fault Code A166: Left rear hydraulic oil temperature sensor is low….507
Fault Code A167: Right rear hydraulic oil temperature sensor is low….508
Fault Code A168: Left front hydraulic oil temperature sensor is low….509
Fault Code A169: Right front hydraulic oil temperature sensor is low….510
Fault Code A170: Left rear hydraulic oil temperature sensor is high….511
Fault Code A171: Right rear hydraulic oil temperature sensor is high….512
Fault Code A172: Left front hydraulic oil temperature sensor is high….513
Fault Code A173: Right front hydraulic oil temperature sensor is high….514
Fault Code A184: J1939 data link is not connected….515
Fault Code A190: Auto lube control has detected an incomplete lube cycle….516
Fault Code A194: Left front hydraulic oil temperature is high….517
Fault Code A195: Right front hydraulic oil temperature is high….518
Fault Code A196: Left rear hydraulic oil temperature is high….519
Fault Code A197: Right rear hydraulic oil temperature is high….520
Fault Code A198: Hoist pressure 1 sensor is high….521
Fault Code A199: Hoist pressure 2 sensor is high….522
Fault Code A200: Steering pressure sensor is high….523
Fault Code A201: Brake pressure sensor is high….524
Fault Code A202: Hoist pressure 1 sensor is low….525
Fault Code A203: Hoist pressure 2 sensor is low….526
Fault Code A204: Steering pressure sensor is low….527
Fault Code A205: Brake pressure sensor is low….528
Fault Code A206: Ambient temperature sensor is high….529
Fault Code A207: Ambient temperature sensor is low….530
Troubleshooting by fault code, Part 3….532
Fault Code A212: Bad truck speed signal….534
Fault Code A213: Parking brake should have applied but is detected as not having applied….535
Fault Code A214: Parking brake should have released but is detected as not having released….537
Fault Code A215: Brake auto apply valve circuit is defective….539
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit….541
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted….542
Fault Code A230: Parking brake has been requested while truck still moving….543
Fault Code A231: The body is up with engine running and brakes not on….544
Fault Code A235: Steering accumulator is in the process of being bled down….545
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds….546
Fault Code A237: The CAN/RPC connection to the display is open….547
Fault Code A240: The key switch input to the interface module is open….548
Fault Code A242: Fuel gauge within the dash display panel is defective….549
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective….550
Fault Code A244: Drive system temperature gauge within the dash display panel is defective….551
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective….552
Fault Code A246: Payload meter reports truck overload….553
Fault Code A247: Low steering pressure warning….554
Fault Code A248: Status module within the dash display panel is defective….555
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted….556
Fault Code A250: Battery voltage is low with the truck parked….557
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground….559
Fault Code A252: Start enable output circuit is either open or shorted to ground….560
Fault Code A253: Steering bleed circuit is not open while running….561
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open….562
Fault Code A257: Payload CAN/RPC is not connected….563
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective….564
Troubleshooting by fault code, Part 4….566
Fault Code A260: Parking brake failure….568
Fault Code A261: Low brake accumulator pressure warning….569
Fault Code A262: Steering bleed valve circuit open during shutdown….570
Fault Code A264: Parking brake relay circuit is defective….571
Fault Code A265: Service brake failure….572
Fault Code A266: Shift lever was not in park while attempting to crank engine….573
Fault Code A267: Parking brake was not set while attempting to crank engine….574
Fault Code A268: Secondary engine shutdown while cranking….575
Fault Code A270: Brake lock switch power supply is not on when required….576
Fault Code A271: Shift lever not in gear….578
Fault Code A272: Brake lock switch power supply is not off when required….579
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit….581
Fault Code A274: A brake setting fault has been detected….582
Fault Code A275: A starter has been detected as engaged without a cranking attempt….583
Fault Code A276: The drive system data link is not connected….584
Fault Code A277: Parking brake applied while loading….585
Fault Code A278: Service brake applied while loading….586
Fault Code A279: Low steering pressure switch is defective….587
Fault Code A280: Steering accumulator bleed down switch is defective….588
Fault Code A281: Brake lock degrade switch is defective….589
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7….590
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set….591
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated….592
Fault Code A285: The parking brake was not set when the keyswitch was turned off….593
Fault Code A286: A fault was detected in the shutdown delay relay circuit….594
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off….595
Troubleshooting by fault code, Part 5….598
Fault Code A303: Shift lever is defective….600
Fault Code A304: Auto lube grease level fault….601
Fault Code A305: Auto lube circuit is defective….602
Fault Code A307: Both GE inverters are disabled….603
Fault Code A309: No brakes applied when expected….604
Fault Code A310: Low fuel warning….605
Fault Code A311: Brake lock switch is on when it should not be….606
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings….607
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings….608
Fault Code A315: DCDC converter 12 volt circuit is low….609
Fault Code A316: Starter engagement has been attempted with engine running….610
Fault Code A317: Operation of brake auto apply valve without a detected response….611
Fault Code A318: Unexpected power loss to interface module….613
Fault Code A320: Data link reports GE propel system caution fault but wired input does not….614
Fault Code A321: Data link reports GE propel system temperature caution fault but wired input does not….615
Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not….616
Fault Code A323: Data link reports GE reduced retard level fault but wired input does not….617
Fault Code A324: Data link reports DC link voltage but wired input does not….618
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not….619
Fault Code A326: Data link reports GE no propel fault but wired input does not….620
Fault Code A327: Data link reports GE at rest but wired input does not….621
Fault Code A328: Drive system not powered up….622
Fault Code A329: Data link reports the body is not down but wired input says it is….623
Fault Code A330: Data link reports dynamic retard operating state but wired input does not….624
Fault Code A332: Seat belt not buckled….625
Fault Code A333: The hydraulic ladder controller has declared a ladder fault….627
Fault Code A334: Shift lever not in park when propel was either not ready or at rest…..628
Troubleshooting by fault code, Part 6….630
Fault Code A350: Overload on output 1B….632
Fault Code A351: Overload on output 1E….633
Fault Code A352: Overload on output 1H….634
Fault Code A353: Overload on output 1J….635
Fault Code A354: Overload on output 1K….636
Fault Code A355: Overload on output 1L….637
Fault Code A356: Overload on output 1M….638
Fault Code A357: Overload on output 1N….639
Fault Code A358: Overload on output 1P….640
Fault Code A359: Overload on output 1R….641
Fault Code A360: Overload on output 1S….642
Fault Code A361: Overload on output 1T….643
Fault Code A362: Overload on output 1U….644
Fault Code A363: Overload on output 1X….645
Fault Code A364: Overload on output 1Y….646
Fault Code A365: Overload on output 1Z….647
Orbcomm….650
Orbcomm satellite connection….652
Required equipment….652
Truck has never communicated with Orbcomm….652
Poor connection or no connection to WebCARE….653
Confirmed satellite communication but not reporting correctly to WebCARE….657
Cab air conditioning….660
Preliminary checks….662
Diagnosis of gauge readings and system performance….662
Troubleshooting by manifold gauge set readings….663
50 Disassembly and assembly….670
Service tools….670
Special tool group….672
Additional service tools….672
Locally made tools….673
Wheels, spindles and rear axle….676
General precautions for tires and rims….678
Rim components….679
Smart rim component layout….679
Wheel stud maintenance….680
Removal and installation of front wheel….681
Removal….681
Installation….682
Removal and installation of rear wheel….683
Removal….683
Installation….684
Rim and tire service….686
Lubricants….686
Tire inflation….686
Lock ring retainer installation….686
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual….687
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual….688
Removal (5-piece standard rim)….689
Removal (7-piece Smart rim)….692
Removal (5-piece Smart rim)….694
Preparation before assembly….696
Installation (5-piece standard rim)….696
Installation – horizontal mount (Smart rim)….698
Installation – vertical mount (5-piece Smart rim)….700
Installation – vertical mount (7-piece Smart rim)….702
Removal and installation of front wheel hub and spindle….703
Removal….703
Spindle removal (off the truck)….708
Installation….710
Disassembly and assembly of front wheel hub and spindle….711
Cross Section View….711
Disassembly….712
Cleaning and inspection….718
Assembly….719
Wheel bearing adjustment….720
Seal assembly gap adjustment….721
Seal installation….722
Brake installation….724
Speed sensor installation and adjustment….726
Hub floating ring seal assembly and installation….727
Removal and installation of rear axle….732
Removal….732
Cleaning and inspection….733
Installation….734
Removal and installation of anti-sway bar….734
Removal….734
Installation….737
Removal and installation of pivot pin….738
Removal….738
Installation….739
Pivot eye and bearing service….740
Bearing replacement….740
Pivot eye repair….741
Removal and installation of wheel motor….742
Preparation….742
Removal….742
Cleaning and inspection….745
Installation….745
Removal and installation of rear brake assembly….749
Brake system….752
Removal and installation of brake valve….754
Removal….754
Installation….756
Disassembly and assembly of brake valve….757
Disassembly….757
Cleaning and inspection….758
Assembly….760
Removal and installation of dual relay valve….764
Removal….764
Installation….765
Disassembly and assembly of dual relay valve….766
Disassembly….766
Cleaning and inspection….767
Assembly….767
Removal and installation of brake manifold….768
Removal….768
Installation….768
Disassembly and assembly of brake manifold….769
Disassembly….769
Assembly….769
Removal and installation of piston brake accumulator….770
Removal….770
Installation….772
Disassembly and assembly of piston brake accumulator….772
Disassembly….772
Cleaning and inspection….774
Piston seal replacement….774
Assembly….775
Disassembly and assembly of front wheel brake….776
Disassembly….776
Cleaning and inspection….779
Assembly….780
Disassembly and assembly of rear wheel brake….782
Disassembly….782
Cleaning and inspection….786
Assembly….787
Brake floating ring seal assembly and installation….790
Removal and installation of parking brake….796
Removal….796
Installation….798
Disassembly and assembly of parking brake….798
Disassembly….798
Cleaning and inspection….800
Cleaning and inspecting new discs….802
Assembly….803
Steering system….806
Removal and installation of steering control unit….808
Removal….808
Installation….809
Disassembly and assembly of steering control unit….810
Disassembly….810
Assembly….812
Removal and installation of steering column….815
Removal….815
Inspection….816
Installation….817
Removal and installation of steering wheel….818
Removal….818
Installation….818
Removal and installation of bleeddown manifold….819
Removal….819
Installation….820
Removal and installation of flow amplifier….821
Removal….821
Installation….822
Removal and installation of steering cylinders and tie rod….823
Removal….823
Installation….823
Disassembly and assembly of steering cylinders….825
Disassembly….825
Cleaning and inspection….827
Assembly….827
Removal and installation of steering/brake pump….828
Removal….828
Installation….829
Removal and installation of piston steering accumulator….830
Removal….830
Installation….832
Disassembly and assembly of piston steering accumulator….832
Disassembly….832
Cleaning and inspection….834
Piston seal replacement….834
Assembly….835
Suspensions….838
Removal and installation of front suspension….840
General information….840
Removal….840
Installation….842
Upper mounting joint – 60° advance….846
Lower mounting joint – 90° advance….847
Inspection….847
Disassembly and assembly of front suspension….848
Disassembly….848
Cleaning and inspection….851
Assembly….851
Removal and installation of rear suspension….853
General information….853
Removal….853
Installation….856
Disassembly and assembly of rear suspension….857
Disassembly….857
Cleaning and inspection….859
Assembly….860
Hoist circuit….862
Removal and installation of hoist pump….864
Removal….864
Installation….869
Disassembly and assembly of hoist pump….870
Disassembly….870
Inspection….875
Assembly….876
Removal and installation of hoist valve….879
Removal….879
Installation….883
Disassembly and assembly of hoist valve….883
O-ring replacement….883
Disassembly of inlet section….885
Assembly of inlet section….886
Disassembly of rear spool section….887
Assembly of rear spool section….889
Disassembly of front spool section….890
Assembly of front spool section….891
Overcenter manifold service….891
Removal and installation of hoist pilot valve….892
Removal….892
Installation….892
Disassembly and assembly of hoist pilot valve….893
Disassembly….893
Cleaning and inspection….894
Assembly….894
Removal and installation of hoist cylinders….895
Removal….895
Installation….897
Disassembly and assembly of hoist cylinders….898
Disassembly….898
Cleaning and inspection….902
Installation of the quill….903
Assembly….905
Body and structures….910
Removal and installation of dump body….912
Removal….912
Inspection….913
Installation….914
Removal and installation of body pads….915
Removal….915
Installation….915
Body pad shimming procedure….916
Removal and installation of diagonal ladder/hood and grille assembly….917
Removal….917
Installation….917
Removal and installation of RH deck….919
Removal….919
Installation….919
Removal and installation of LH deck….921
Removal….921
Installation….921
Removal and installation of fuel tank….923
Removal….923
Cleaning and inspection….923
Installation….925
Removal and installation of fuel gauge sender….925
Removal….925
Installation….925
Removal and installation of hydraulic tank….926
Removal….926
Installation….927
Removal and installation of hydraulic tank strainers….928
Removal….928
Cleaning and inspection….929
Installation….929
Operator cab….932
Removal and installation of operator cab….934
Removal….934
Installation….937
Removal and installation of cab door….937
Removal….937
Installation….938
Disassembly and assembly of cab door….939
Removing inner door panel….939
Installing inner door panel….940
Replacing the door window regulator….940
Replacing door handle or latch assembly….941
Replacing door assembly seal and door hinge seal….942
Replacing door opening seal….942
Removing door glass….943
Installing door glass….944
Adjustment of cab door….946
Door jamb bolt adjustment….946
Door handle plunger adjustment….947
Removal and installation of side window glass….948
Recommended tools and supplies….948
Removal….949
Installation….949
Removal and installation of windshield and rear window glass….950
Removal….950
Installation….950
Removal and installation of windshield wiper motor….951
Removal….951
Installation….952
Removal and installation of windshield wiper arm….952
Removal….952
Installation….952
Removal and installation of windshield wiper linkage….953
Removal….953
Installation….953
Removal and installation of optional seats….954
Removal….954
Installation….954
Removal and installation of seat belts (optional seats)….955
General….955
Removal….955
Installation….957
Removal and installation of electronic accelerator and retard pedals….959
Removal….959
Installation….959
Disassembly….959
Assembly….959
Cab air conditioning….962
Replacement of air conditioning system components….964
Hoses and fittings….964
Lines….964
Expansion valve….964
Receiver-drier….964
Thermostat….964
Compressor….965
Accumulator….965
Clutch….965
Power module….968
Removal and installation of power module….970
General….970
Removal….971
Installation….979
Removal and installation of alternator….982
Removal….982
Installation….985
Removal and installation of radiator….994
Removal….994
Installation….999
Repairing the radiator….1000
Internal inspection….1000
External cleaning….1000
Disassembly….1000
Cleaning and inspection….1001
Assembly….1002
Pressure testing….1003
Removal and installation of engine….1003
Removal….1003
Service….1003
Installation….1004
90 Diagrams and drawings….1006
Hydraulic circuit diagrams….1006
Steering, hoist & brake cooling….1008
Brake hydraulics….1009
Auxiliary system hydraulics….1010
Electrical circuit diagrams….1013
Electrical system….1015
Electrical sub-systems….1039
CEBM031601 – 980E-4 Dump Truck Shop Manual (SN A40052 & up, Engine 18V170)….1072
00 Index and foreword….1074
Index….1074
Composition of shop manual….1075
Table of contents….1077
Foreword, safety and general information….1090
Foreword….1093
How to read the shop manual….1094
Composition of shop manual….1094
Revision and distribution….1094
Symbols….1095
General safety….1096
Safety rules….1096
Safety features….1096
Fire extinguisher and first aid kit….1096
Clothing and personal items….1096
Leaving the operator seat….1097
Mounting and dismounting….1097
Fire prevention for fuel and oil….1097
Precautions with high temperature fluids….1098
Asbestos dust hazard prevention….1098
Prevention of injury by work equipment….1098
Unauthorized modification….1098
Precautions when using ROPS….1098
Precautions for attachments….1099
Precautions for starting the truck….1099
Precautions before operating the truck….1099
Safety at the worksite….1099
Fire prevention….1100
Ventilation in enclosed areas….1100
Preparing for operation….1100
Mirrors, windows and lights….1100
In operator cab (before starting the engine)….1100
Seat Belts….1100
Precautions while operating the truck….1101
When starting the engine….1101
General truck operation….1101
Ensuring good visibility….1101
Traveling….1102
Traveling in reverse….1102
Traveling on slopes….1102
Operating on snow or ice….1102
Avoid damage to dump body….1102
Driving near high voltage cables….1103
When dumping….1103
When loading….1103
Working on loose ground….1103
Parking the truck….1103
Towing….1103
Working near batteries….1104
Battery hazard prevention….1104
Starting with jumper cables….1105
Jump starting with receptacles….1105
Precautions before performing service….1106
Warning tag….1106
Stopping the engine….1106
Proper tools….1106
Use of Tie-Off Anchor During Maintenance and Repair….1106
Securing the dump body….1107
Jack point locations….1108
Precautions while performing service….1109
Keep the truck clean….1109
Attachments….1109
Working under the truck….1109
Rotating fan and belts….1109
Adding fuel or oil….1109
Use of lighting….1109
Radiator coolant level….1110
Precautions with the battery….1110
Precautions with high pressure oil….1110
Handling high pressure hoses….1110
Precautions when performing maintenance near high temperature or high pressure….1110
Waste materials….1110
Tires….1111
Inspection….1111
Maintenance….1111
Storage….1112
Handling….1113
Precautions for performing repairs….1114
Engine shutdown procedure after AC drive system failure….1114
Precautions for welding on the truck….1115
Capacitor discharge system….1116
Necessary tools….1116
Warnings and cautions….1117
Manual DC link capacitor discharge procedure….1118
Failure of the discharge system….1120
Manual discharge of capacitors….1121
Short isolated capacitor terminals….1123
Handling electrical equipment and hydraulic components….1124
Points to remember when handling electrical equipment….1124
Points to remember when handling hydraulic equipment….1130
Standard tightening torques….1132
Effect of special lubricants on fasteners and standard torque values….1132
Suggested sources for rust preventive grease….1132
SAE grade 5 and grade 8 hex head capscrew and nut assemblies….1133
SAE grade 9 capscrews….1134
Class 10.9 capscrews and class 10 nuts….1134
Standard tightening torques for fittings….1135
Conversion tables….1137
Common conversion multipliers….1137
01 Specification….1142
Specification and technical data….1142
Specification drawing….1144
Specifications….1145
Weight table….1147
Fuel, coolant and lubricants….1148
Suspension cylinder oil and nitrogen specifications….1149
10 Structure, functions and maintenance standard….1152
Steering circuit….1152
Steering circuit operation….1153
Steering circuit components….1158
Steering control unit….1158
High pressure filter….1158
Steering accumulators….1158
Bleeddown manifold….1159
Steering accumulator bleeddown solenoid….1159
Hoist up limit solenoid….1159
Quick disconnect ports….1159
Flow amplifier….1159
Steering/brake pump operation….1160
High altitude operation….1160
Neutral position….1161
Full pump volume….1162
Half pump volume….1162
Flow amplifier operation….1163
No steer….1163
Steering left….1165
Steering right….1167
No steer, external shock load….1169
Hoist circuit….1172
Hoist circuit operation….1174
Hoist circuit components….1175
Hydraulic tank….1175
Hoist pump….1175
High pressure filters….1175
Hoist valve….1176
Inlet sections….1176
Tank ports (front) spool section….1176
Work ports (rear) spool section….1177
Hoist pilot valve….1177
Hoist limit solenoid….1178
Pilot operated check valve….1178
Overcenter manifold….1178
Hoist pilot valve operation….1179
Float position with body down….1179
Power up operation….1181
Hold operation….1183
Power down operation….1185
Float operation….1187
Brake circuits….1190
General information….1192
Service brake circuit operation….1193
Secondary braking….1195
Automatic brake application (Auto apply)….1195
Parking brake circuit operation….1196
Normal operation (key switch ON, engine on)….1196
Wheel brake lock circuit operation….1197
Brake warning circuit operation….1197
Brake assembly wear data….1199
Electrical system, 24 volt….1202
Battery supply system….1204
Batteries….1204
24VDC auxiliary battery receptacles….1204
Engine shutdown switch….1205
Battery disconnect switches….1205
Propel lockout lever….1205
System busy light….1205
LED lights….1205
Engine starting system with prelube….1206
Prelube operation….1206
Cranking operation….1207
Auxiliary control cabinet components….1208
24VDC to 12VDC converter….1208
Interface module (IM)….1208
VEC blocks….1209
Light timers….1209
Relays….1209
Ground terminals….1209
24VDC power terminals….1209
Body-up switch….1210
Hoist limit switch….1211
Electrical system, AC drive….1214
General system operation….1215
System components….1217
Drive system controller (DSC)….1217
Diagnostic information display (DID) panel….1218
DSC software functions….1218
Input processing….1218
State machine….1218
DC link state….1221
Engine control….1222
Alternator field control….1223
Desired DC link voltage….1223
Self-load….1223
Propel torque control….1223
Retard torque control….1224
Wheel slide control….1224
Resistor grid control….1224
Chopper voltage control….1224
Event detection and processing….1225
Power-on tests….1225
Initiated tests….1226
Periodic tests….1226
Event restrictions….1226
Event logging and storage….1226
Data packs….1227
Event reset….1227
Abnormal conditions/overriding functions….1228
Engine shutdown/Engine not running….1228
Limp home mode….1228
AC drive system component table….1229
Electronic accelerator and retarder pedals….1236
Cab air conditioning….1238
General information….1239
Environmental impact of air conditioning….1239
Air conditioning for off-highway vehicles….1239
Principles of refrigeration….1240
Air conditioning….1240
Refrigeration – the act of cooling….1240
The refrigeration cycle….1240
Air conditioning system components….1242
Relays….1242
Fan motor and speed control….1242
Cab air filter….1242
Heater core….1242
Actuators….1242
Compressor (refrigerant pump)….1244
Service valves….1244
Condenser….1244
Receiver-drier….1244
Expansion valve….1245
Accumulator….1245
Evaporator core….1245
Air conditioning system electrical circuit….1246
Thermostat….1246
Compressor clutch….1246
Trinary™ switch….1247
Reserve engine oil system….1250
General information….1252
Operation….1253
Pumping unit….1253
LED monitor lights….1254
Tank auto fill control….1255
Filling procedure (remote fill feature)….1255
Service….1256
Every 10 hours (each shift)….1256
Every 500 hours….1256
Changing oil….1256
Troubleshooting….1257
Circuit fuses….1257
Auto fill system electrical schematic….1258
20 Standard value table….1260
Standard value table….1260
Standard value table for truck….1262
30 Testing and adjusting….1268
Steering, brake cooling and hoist hydraulic system….1268
General information on system checkout….1270
Hydraulic system checkout procedures….1271
Required equipment….1271
Bleeddown procedure….1271
Preliminary steps….1273
Hydraulic system flushing procedure….1273
Flow amplifier adjustment….1277
Steering pump unloader valve adjustment….1277
Auxiliary accumulator pressure verification….1278
System diagnostics….1278
Hoist counterbalance valve adjustment….1280
Final steps….1281
Oil cleanliness check….1281
Hydraulic system checkout data sheet….1282
Toe-in adjustment….1285
Hoist cylinder leakage test….1286
Steering cylinder leakage test….1286
Brake system….1288
General information on system checkout….1290
Brake system checkout procedures….1290
Required equipment….1290
Initial system setup….1292
Brake lock / secondary braking checkout….1292
Parking brake checkout….1293
Service brake checkout….1294
Low brake accumulator pressure and auto apply checkout….1295
Parking brake control logic checkout….1297
Brake lock control logic checkout….1298
Brake system checkout data sheet….1301
Brake piston leakage test….1309
Brake seal pressure test….1309
Oil separator seal pressure test….1309
Wet disc brake bleeding procedure….1310
Parking brake bleeding procedure….1311
Service brake disc wear inspection….1312
Parking brake disc wear inspection….1313
Brake valve bench test and adjustment….1314
Test setup procedure….1315
Brake valve output pressure adjustment….1315
Final test and adjustment….1316
Dual relay valve bench test and adjustment….1317
Test setup procedure….1318
Relay valve output pressure adjustment….1318
Accumulators and suspensions….1320
Accumulator charging precautions….1321
Temperature during precharge….1321
Bladder accumulator charging procedure….1322
Precharge maintenance….1325
Bladder accumulator storage….1326
Bladder storage….1326
Installing a bladder accumulator from storage….1326
Bladder accumulator leak testing….1327
Piston accumulator charging procedure….1328
Piston accumulator storage….1330
Piston accumulator leak testing….1330
Checking for improper suspension charge….1331
Suspension oiling and charging procedures….1332
Required equipment….1332
Installing the charging kit….1333
Removing the charging kit….1333
Support blocks for oiling and charging dimensions….1334
Front suspensions….1335
Rear suspensions….1338
Suspension pressure test….1341
Interface module (IM)….1344
Interface module software….1346
Flashburn program installation….1346
Interface module application code installation….1347
Interface module realtime data monitor software installation….1347
Interface module checkout procedures….1348
Necessary equipment….1348
Preliminary….1349
Check digital inputs to the interface module….1350
Check analog inputs to the interface module….1353
Check serial interfaces to the interface module….1353
Check outputs from the interface module….1354
CHECKOUT PROCEDURE….1355
KOMTRAX Plus….1360
KOMTRAX Plus software and tools….1362
KOMTRAX Plus controller setup procedure….1362
Preliminary steps….1362
Setup procedure….1362
KOMTRAX Plus initialization form….1366
Precautions when replacing the KOMTRAX Plus controller….1367
KOMTRAX Plus controller checkout procedure….1369
Preliminary steps….1369
Checkout procedure….1369
Payload meter IV….1372
Payload meter IV software and tools….1373
Payload meter IV system configuration….1373
Connecting to the payload meter IV web server….1373
Configuring a static IP address….1373
Payload meter IV software installation….1375
Payload meter IV checkout procedure….1376
PLM IV system checkout data sheet….1380
Komatsu wireless bridge (KWB)….1382
General information….1383
Software download and setup….1384
Bullet M2 Titanium / PicoStation M2….1385
Bullet M2….1387
Configuring a KWB_Connect device….1388
Access point configuration….1388
Bullet M2 configuration….1389
KOMTRAX Plus downloads….1390
Configuring a TRUCK_NET device….1391
Access point configuration….1391
Bullet M2 configuration….1392
Onboard controller access….1393
Changing a service computer’s IP address….1394
Connecting to a wireless network….1395
KWB_Connect troubleshooting….1396
Step 1. Verify communication to the access point….1396
Step 2. Verify communication to the Bullet M2….1396
Step 3. Verify communication to KOMTRAX Plus….1397
TRUCK_NET troubleshooting….1398
Step 1. Verify communication to the access point….1398
Step 2. Verify communication to the Bullet M2….1399
KWB_Connect checkout data sheet….1400
TRUCK_NET checkout data sheet….1401
Electrical system, AC drive….1404
General information….1405
Test equipment….1405
Circuit continuity and resistance checks….1405
Megger test for grounds….1406
Troubleshooting for grounds….1409
Low voltage power supply checks….1409
Drive System Controller (DSC) card checks….1410
Propulsion system software installation….1411
Software installation procedure….1412
DSC manual test procedures….1413
Accelerator pedal, retarder pedal, and retarder lever calibration and checks….1416
Set truck ID number….1420
Control cabinet pressure switch check….1421
Checks prior to self load engine test (loadbox)….1423
Verifying DSC Software Version….1423
Resetting and erasing DSC event data….1424
Engine running tests….1425
Battery boost circuit verification….1425
Selector switch check….1428
Ground detection network tests….1430
Self load engine test (loadbox) procedure….1435
Diagnostic information display (DID) panel….1437
DID panel display selection….1437
DID modes display….1439
Function key F1 – DID events or faults display….1440
Function key F4 – DID menu display….1443
DID self load engine test (loadbox)….1444
DID link capacitance test….1446
DID speedometer test….1447
DID view software version….1449
DID view overspeed setting….1451
DID view data menu….1452
DID inverter cutout menu….1457
DID truck configuration menu….1459
Language selection….1466
Viewing event and statistical data….1467
Viewing the DSC event summary, trigger data, and data packs….1467
Viewing the statistical data….1470
Logic screens….1471
Datalogger function….1473
Setting up the datalogger….1473
Starting the datalogger….1475
Uploading data….1477
Consolidated truck data save….1477
USB drive….1478
Cab air conditioning….1480
General information….1482
Service tools and equipment….1483
Recovery/recycle station….1483
Leak detector….1483
Manifold gauge set….1484
Service valves….1485
Vacuum pump….1485
Detecting leaks….1486
System performance test….1487
Checking system oil….1488
System flushing….1489
Installing the manifold gauge set….1490
Purging air from the service hoses….1490
Recovering and recycling refrigerant….1491
Draining oil from previous recovery cycle….1492
Recovery cycle….1492
Recycling procedure….1492
Evacuating the air conditioning system….1493
Charging the air conditioning system….1494
40 Troubleshooting….1496
Fuse, diode and relay locations….1496
Vehicle Electrical Center (VEC-89)….1497
Vehicle Electrical Center (VEC-90)….1499
Vehicle Electrical Center (VEC-91)….1501
Vehicle Electrical Center (RTMR1)….1503
AC drive system fault codes (DSC)….1506
DID panel fault code tables….1508
Troubleshooting by fault code, Part 1….1532
Fault Code A001: Left front suspension pressure sensor signal high….1534
Fault Code A002: Left front suspension pressure sensor signal low….1535
Fault Code A003: Right front suspension pressure sensor signal high….1536
Fault Code A004: Right front suspension pressure sensor signal low….1537
Fault Code A005: Left rear suspension pressure sensor signal high….1538
Fault Code A006: Left rear suspension pressure sensor signal low….1539
Fault Code A007: Right rear suspension pressure sensor signal high….1540
Fault Code A008: Right rear suspension pressure sensor signal low….1541
Fault Code A009: Incline sensor signal high….1542
Fault Code A010: Incline sensor signal low….1543
Fault Code A011: Payload meter speed sensor signal has failed….1544
Fault Code A013: Body up switch has failed….1545
Fault Code A014: Payload meter checksum computation has failed….1546
Fault Code A018: Right rear flat suspension cylinder warning….1547
Fault Code A019: Left rear flat suspension cylinder warning….1549
Fault Code A022: Carryback load excessive….1551
Fault Code A101: High pressure detected across an hydraulic pump filter….1553
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level….1555
Fault Code A107: GE has generated a propel system caution….1556
Fault Code A108: GE has generated a propel system temperature caution….1557
Fault Code A109: GE has generated a propel system reduced level signal….1558
Fault Code A111: Low steering pressure warning….1559
Fault Code A115: Low steering precharge pressure detected….1562
Fault Code A117: Low brake accumulator pressure warning….1564
Fault Code A118: Brake pressure is low while in brake lock….1566
Fault Code A123: GE has generated a reduced retarding caution….1568
Fault Code A124: GE has generated a no propel / no retard warning….1569
Fault Code A125: GE has generated a no propel warning….1571
Fault Code A126: Oil level in the hydraulic tank is low….1572
Fault Code A127: IM-furnished +5 volt output for sensors is low….1573
Fault Code A128: IM-furnished +5 volt output for sensors is high….1574
Fault Code A139: Low fuel warning….1575
Troubleshooting by fault code, Part 2….1578
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil….1580
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil….1581
Fault Code A152: Starter failure….1582
Fault Code A153: Battery voltage is low with the truck in operation….1583
Fault Code A154: Battery charging voltage is excessive….1585
Fault Code A155: Battery charging voltage is low….1586
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level….1587
Fault Code A166: Left rear hydraulic oil temperature sensor is low….1589
Fault Code A167: Right rear hydraulic oil temperature sensor is low….1590
Fault Code A168: Left front hydraulic oil temperature sensor is low….1591
Fault Code A169: Right front hydraulic oil temperature sensor is low….1592
Fault Code A170: Left rear hydraulic oil temperature sensor is high….1593
Fault Code A171: Right rear hydraulic oil temperature sensor is high….1594
Fault Code A172: Left front hydraulic oil temperature sensor is high….1595
Fault Code A173: Right front hydraulic oil temperature sensor is high….1596
Fault Code A184: J1939 data link is not connected….1597
Fault Code A190: Auto lube control has detected an incomplete lube cycle….1599
Fault Code A194: Left front hydraulic oil temperature is high….1601
Fault Code A195: Right front hydraulic oil temperature is high….1602
Fault Code A196: Left rear hydraulic oil temperature is high….1603
Fault Code A197: Right rear hydraulic oil temperature is high….1604
Fault Code A198: Hoist pressure 1 sensor is high….1605
Fault Code A199: Hoist pressure 2 sensor is high….1606
Fault Code A200: Steering pressure sensor is high….1607
Fault Code A201: Brake pressure sensor is high….1608
Fault Code A202: Hoist pressure 1 sensor is low….1609
Fault Code A203: Hoist pressure 2 sensor is low….1610
Fault Code A204: Steering pressure sensor is low….1611
Fault Code A205: Brake pressure sensor is low….1612
Fault Code A206: Ambient temperature sensor is high….1613
Fault Code A207: Ambient temperature sensor is low….1614
Troubleshooting by fault code, Part 3….1618
Fault Code A212: Bad truck speed signal….1621
Fault Code A213: Parking brake should have applied but is detected as not having applied….1622
Fault Code A214: Parking brake should have released but is detected as not having released….1625
Fault Code A215: Brake auto apply valve circuit is defective….1628
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit….1630
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted….1632
Fault Code A230: Parking brake has been requested while truck still moving….1634
Fault Code A231: The body is up with engine running and brakes not on….1636
Fault Code A233: Drive system CAN/RPC Control Link not connected….1639
Fault Code A235: Steering accumulator is in the process of being bled down….1641
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds….1643
Fault Code A237: The CAN/RPC connection to the display is open….1645
Fault Code A240: The key switch input to the interface module is open….1646
Fault Code A242: Fuel gauge within the dash display panel is defective….1648
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective….1649
Fault Code A244: Drive system temperature gauge within the dash display panel is defective….1650
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective….1651
Fault Code A246: Payload meter reports truck overload….1652
Fault Code A247: Low steering pressure warning….1653
Fault Code A248: Status module within the dash display panel is defective….1655
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted….1656
Fault Code A250: Battery voltage is low with the truck parked….1657
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground….1659
Fault Code A252: Start enable output circuit is either open or shorted to ground….1661
Fault Code A253: Steering bleed circuit is not open while running….1663
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open….1665
Fault Code A257: Payload CAN/RPC is not connected….1666
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective….1667
Troubleshooting by fault code, Part 4….1670
Fault Code A260: Parking brake failure….1672
Fault Code A261: Low brake accumulator pressure warning….1674
Fault Code A262: Steering bleed valve circuit open during shutdown….1675
Fault Code A264: Parking brake relay circuit is defective….1677
Fault Code A265: Service brake failure….1679
Fault Code A266: Shift lever was not in park while attempting to crank engine….1681
Fault Code A267: Parking brake was not set while attempting to crank engine….1683
Fault Code A268: Secondary engine shutdown while cranking….1685
Fault Code A270: Brake lock switch power supply is not on when required….1686
Fault Code A271: Shift lever not in gear….1688
Fault Code A272: Brake lock switch power supply is not off when required….1690
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit….1692
Fault Code A274: A brake setting fault has been detected….1693
Fault Code A275: A starter has been detected as engaged without a cranking attempt….1695
Fault Code A276: The drive system data link is not connected….1697
Fault Code A277: Parking brake applied while loading….1698
Fault Code A278: Service brake applied while loading….1700
Fault Code A279: Low steering pressure switch is defective….1701
Fault Code A280: Steering accumulator bleed down switch is defective….1703
Fault Code A281: Brake lock degrade switch is defective….1705
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7….1707
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set….1709
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated….1711
Fault Code A285: The parking brake was not set when the keyswitch was turned off….1713
Fault Code A286: A fault was detected in the shutdown delay relay circuit….1715
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off….1717
Troubleshooting by fault code, Part 5….1720
Fault Code A303: Shift lever is defective….1722
Fault Code A304: Auto lube grease level fault….1723
Fault Code A305: Auto lube circuit is defective….1724
Fault Code A307: Both GE inverters are disabled….1725
Fault Code A309: No brakes applied when expected….1726
Fault Code A310: Low fuel warning….1728
Fault Code A311: Brake lock switch is on when it should not be….1730
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings….1732
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings….1733
Fault Code A315: DCDC converter 12 volt circuit is low….1734
Fault Code A316: Starter engagement has been attempted with engine running….1736
Fault Code A317: Operation of brake auto apply valve without a detected response….1738
Fault Code A318: Unexpected power loss to interface module….1740
Fault Code A320: Data link reports GE propel system caution fault but wired input does not….1741
Fault Code A321: Data link reports GE propel system temperature caution fault but wired input does not….1742
Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not….1743
Fault Code A323: Data link reports GE reduced retard level fault but wired input does not….1744
Fault Code A324: Data link reports DC link voltage but wired input does not….1745
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not….1746
Fault Code A326: Data link reports GE no propel fault but wired input does not….1747
Fault Code A327: Data link reports GE at rest but wired input does not….1748
Fault Code A328: Drive system not powered up….1749
Fault Code A329: Data link reports the body is not down but wired input says it is….1750
Fault Code A330: Data link reports dynamic retard operating state but wired input does not….1751
Fault Code A332: Seat belt not buckled….1752
Fault Code A333: The hydraulic ladder controller has declared a ladder fault….1754
Fault Code A334: Shift lever not in park when propel was either not ready or at rest….1755
Fault Code A337: Engine Air Filter Circuit Fault….1757
Fault Code A338: Engine Air Filter Fault….1758
Troubleshooting by fault code, Part 6….1760
Fault Code A350: Overload on output 1B….1762
Fault Code A351: Overload on output 1E….1763
Fault Code A352: Overload on output 1H….1765
Fault Code A353: Overload on output 1J….1766
Fault Code A354: Overload on output 1K….1767
Fault Code A355: Overload on output 1L….1768
Fault Code A356: Overload on output 1M….1769
Fault Code A357: Overload on output 1N….1770
Fault Code A358: Overload on output 1P….1771
Fault Code A359: Overload on output 1R….1773
Fault Code A360: Overload on output 1S….1775
Fault Code A361: Overload on output 1T….1776
Fault Code A362: Overload on output 1U….1777
Fault Code A363: Overload on output 1X….1778
Fault Code A364: Overload on output 1Y….1779
Fault Code A365: Overload on output 1Z….1780
Orbcomm….1784
Orbcomm satellite connection….1786
Required equipment….1786
Truck has never communicated with Orbcomm….1786
Poor connection or no connection to WebCARE….1787
Confirmed satellite communication but not reporting correctly to WebCARE….1791
Cab air conditioning….1794
Preliminary checks….1796
Diagnosis of gauge readings and system performance….1796
Troubleshooting by manifold gauge set readings….1797
Steering system….1804
Steering circuit troubleshooting chart….1805
Steering circuit troubleshooting guidelines….1809
Basic hydraulic system checks….1810
System leakage check….1811
Steering pump troubleshooting guide….1813
Pump pressure control checks….1816
Pump fails to unload….1817
Pump fails to develop pressure….1817
Pump slow in developing pressure….1818
Pump control valve inspection and trouble shooting….1818
Pump case drain check….1820
Setting pump pressure controls….1820
50 Disassembly and assembly….1824
Service tools….1824
Special tool group….1826
Additional service tools….1826
Locally made tools….1827
Wheels, spindles and rear axle….1830
General precautions for tires and rims….1832
Rim components….1833
Smart rim component layout….1833
Wheel stud maintenance….1834
Removal and installation of front wheel….1835
Removal….1835
Installation….1836
Removal and installation of rear wheel….1837
Removal….1837
Installation….1838
Rim and tire service….1840
Lubricants….1840
Tire inflation….1840
Lock ring retainer installation….1840
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual….1841
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual….1842
Removal (5-piece standard rim)….1843
Removal (7-piece Smart rim)….1846
Removal (5-piece Smart rim)….1848
Preparation before assembly….1850
Installation (5-piece standard rim)….1850
Installation – horizontal mount (Smart rim)….1852
Installation – vertical mount (5-piece Smart rim)….1854
Installation – vertical mount (7-piece Smart rim)….1856
Removal and installation of front wheel hub and spindle….1857
Removal….1857
Spindle removal (off the truck)….1862
Installation….1864
Disassembly and assembly of front wheel hub and spindle….1865
Cross Section View….1865
Disassembly….1866
Cleaning and inspection….1872
Assembly….1873
Wheel bearing adjustment….1874
Seal assembly gap adjustment….1875
Seal installation….1876
Brake installation….1878
Speed sensor installation and adjustment….1880
Hub floating ring seal assembly and installation….1881
Removal and installation of rear axle….1886
Removal….1886
Cleaning and inspection….1887
Installation….1888
Removal and installation of anti-sway bar….1888
Removal….1888
Installation….1891
Removal and installation of pivot pin….1892
Removal….1892
Installation….1893
Pivot eye and bearing service….1894
Bearing replacement….1894
Pivot eye repair….1895
Removal and installation of wheel motor….1896
Preparation….1896
Removal….1896
Cleaning and inspection….1899
Installation….1899
Removal and installation of rear brake assembly….1903
Brake system….1906
Removal and installation of brake valve….1908
Removal….1908
Installation….1910
Disassembly and assembly of brake valve….1911
Disassembly….1911
Cleaning and inspection….1912
Assembly….1914
Removal and installation of dual relay valve….1918
Removal….1918
Installation….1919
Removal and installation of brake manifold….1920
Removal….1920
Installation….1920
Disassembly and assembly of brake manifold….1921
Disassembly….1921
Assembly….1921
Removal and installation of piston brake accumulator….1922
Removal….1922
Installation….1924
Disassembly and assembly of piston brake accumulator….1924
Disassembly….1924
Cleaning and inspection….1926
Piston seal replacement….1926
Assembly….1927
Disassembly and assembly of front wheel brake….1928
Disassembly….1928
Cleaning and inspection….1931
Assembly….1932
Disassembly and assembly of rear wheel brake….1934
Disassembly….1934
Cleaning and inspection….1938
Assembly….1939
Brake floating ring seal assembly and installation….1942
Removal and installation of parking brake….1948
Removal….1948
Installation….1950
Disassembly and assembly of parking brake….1950
Disassembly….1950
Cleaning and inspection….1952
Cleaning and inspecting new discs….1954
Assembly….1955
Steering system….1958
Removal and installation of steering control unit….1960
Removal….1960
Installation….1961
Disassembly and assembly of steering control unit….1962
Disassembly….1962
Assembly….1964
Removal and installation of steering column….1967
Removal….1967
Inspection….1968
Installation….1969
Removal and installation of steering wheel….1970
Removal….1970
Installation….1970
Removal and installation of bleeddown manifold….1971
Removal….1971
Installation….1972
Removal and installation of flow amplifier….1973
Removal….1973
Installation….1974
Removal and installation of steering cylinders and tie rod….1975
Removal….1975
Installation….1975
Disassembly and assembly of steering cylinders….1977
Disassembly….1977
Cleaning and inspection….1979
Assembly….1979
Removal and installation of steering/brake pump….1980
Removal….1980
Installation….1981
Removal and installation of piston steering accumulator….1982
Removal….1982
Installation….1984
Disassembly and assembly of piston steering accumulator….1984
Disassembly….1984
Cleaning and inspection….1986
Piston seal replacement….1986
Assembly….1987
Suspensions….1990
Removal and installation of front suspension….1992
General information….1992
Removal….1992
Installation….1994
Upper mounting joint – 60° advance….1998
Lower mounting joint – 90° advance….1999
Inspection….1999
Disassembly and assembly of front suspension….2000
Disassembly….2000
Cleaning and inspection….2003
Assembly….2003
Removal and installation of rear suspension….2005
General information….2005
Removal….2005
Installation….2008
Disassembly and assembly of rear suspension….2009
Disassembly….2009
Cleaning and inspection….2011
Assembly….2012
Hoist circuit….2014
Removal and installation of hoist pump….2016
Removal….2016
Installation….2021
Disassembly and assembly of hoist pump….2022
Disassembly….2022
Inspection….2027
Assembly….2028
Removal and installation of hoist valve….2031
Removal….2031
Installation….2035
Disassembly and assembly of hoist valve….2035
O-ring replacement….2035
Disassembly of inlet section….2037
Assembly of inlet section….2038
Disassembly of rear spool section….2039
Assembly of rear spool section….2041
Disassembly of front spool section….2042
Assembly of front spool section….2043
Overcenter manifold service….2043
Removal and installation of hoist pilot valve….2044
Removal….2044
Installation….2044
Disassembly and assembly of hoist pilot valve….2045
Disassembly….2045
Cleaning and inspection….2046
Assembly….2046
Removal and installation of hoist cylinders….2047
Removal….2047
Installation….2049
Disassembly and assembly of hoist cylinders….2050
Disassembly….2050
Cleaning and inspection….2054
Installation of the quill….2055
Assembly….2057
Body and structures….2062
Removal and installation of dump body….2064
Removal….2064
Inspection….2065
Installation….2066
Removal and installation of body pads….2067
Removal….2067
Installation….2067
Body pad shimming procedure….2068
Removal and installation of diagonal ladder/hood and grille assembly….2069
Removal….2069
Installation….2069
Removal and installation of RH deck….2071
Removal….2071
Installation….2071
Removal and installation of LH deck….2073
Removal….2073
Installation….2073
Removal and installation of fuel tank….2075
Removal….2075
Cleaning and inspection….2075
Installation….2077
Removal and installation of fuel gauge sender….2077
Removal….2077
Installation….2077
Removal and installation of hydraulic tank….2078
Removal….2078
Installation….2079
Removal and installation of hydraulic tank strainers….2080
Removal….2080
Cleaning and inspection….2081
Installation….2081
Operator cab….2084
Removal and installation of operator cab….2086
Removal….2086
Installation….2089
Removal and installation of cab door….2089
Removal….2089
Installation….2090
Disassembly and assembly of cab door….2091
Removing inner door panel….2091
Installing inner door panel….2092
Replacing the door window regulator….2092
Replacing door handle or latch assembly….2093
Replacing door assembly seal and door hinge seal….2094
Replacing door opening seal….2094
Removing door glass….2095
Installing door glass….2096
Adjustment of cab door….2098
Door jamb bolt adjustment….2098
Door handle plunger adjustment….2099
Removal and installation of side window glass….2100
Recommended tools and supplies….2100
Removal….2101
Installation….2101
Removal and installation of windshield and rear window glass….2102
Removal….2102
Installation….2102
Removal and installation of windshield wiper motor….2103
Removal….2103
Installation….2104
Removal and installation of windshield wiper arm….2104
Removal….2104
Installation….2104
Removal and installation of windshield wiper linkage….2105
Removal….2105
Installation….2105
Removal and installation of optional seats….2106
Removal….2106
Installation….2106
Removal and installation of seat belts (optional seats)….2107
General….2107
Removal….2107
Installation….2109
Removal and installation of electronic accelerator and retard pedals….2111
Removal….2111
Installation….2111
Disassembly….2111
Assembly….2111
Cab air conditioning….2114
Replacement of air conditioning system components….2116
Hoses and fittings….2116
Lines….2116
Expansion valve….2116
Receiver-drier….2116
Thermostat….2116
Compressor….2117
Accumulator….2117
Clutch….2117
Power module….2120
Removal and installation of power module….2122
General….2122
Removal….2123
Installation….2131
Removal and installation of alternator….2134
Removal….2134
Installation….2137
Removal and installation of radiator….2146
Removal….2146
Installation….2151
Repairing the radiator….2152
Internal inspection….2152
External cleaning….2152
Disassembly….2152
Cleaning and inspection….2153
Assembly….2154
Pressure testing….2155
Removal and installation of engine….2155
Removal….2155
Service….2155
Installation….2156
90 Diagrams and drawings….2158
Hydraulic circuit diagrams….2158
Electrical circuit diagrams….2166
Blank Page….1073
Blank Page….2163
Komatsu 980E Dump Trucks Repair Service Manuals