Remote Monitoring & Diagnostics

Troubleshooting and Repair Recommendation

Fault Code A115: Low steering precharge pressure detected

Operator Action Stop; Park
Fault Code A115
Description Low steering precharge pressure is detected.
Fault Conditions Sets and latches if low steering precharge switch operates for 2 seconds with key-
switch on and "Steering Precharge Mask" not on. The "Steering Precharge Mask" pre-
vents warnings that might occur from the beginning of steering bleed till 5 minutes after
bleed is complete or timed out or keyswitch is turned back on.
Resets when steering bleed comes on. Mask prevents new operations for 5 minutes.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP: PARK
Display Fault Description: LOW STRG PRECHARGE
Display Fault Code: A115
Resulting Problem(s) Low steering accumulator precharge will reduce the amount of stored energy in the
steering system.
Related Information A laptop running "IM Realtime Data Monitor" software may be required to resolve this
fault.

Table
1. The primary correction for this fault is to adjust the nitrogen charge in the steering accumulators.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes, then based on the truck's setup while this fault is active, deter-
mine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Monitor
program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the unex-
pected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the malfunc-
tion is still unresolved, then check each of the parameters in the Table for proper functionality. Troubleshoot all
item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Low Steering 0: Normal reading - full precharge pressure
Precharge Pressure 1: Steering precharge pressure is low
Switch (IM2W)
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving (GE power not yet off)
Fault(s): A240
Steering Bleed Valve 0: steering bleed valve is off
1: steering bleed valve is on
Steering Accumulator 0: Steering bleed is complete
Bleed Pressure Switch 1: Steering bleed is not complete
(IM2Z) Fault(s): A258, A280

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 Remote Monitoring & Diagnostics
Troubleshooting and Repair Recommendation

Troubleshooting
The cause for low nitrogen precharge pressure can be due to the precharge being permanently below specifications or
temprarily created due to operational events such as:

1. The engine is shut down and restarted less than 2 minutes after the accumulators have completed the bleed down cycle.
2. After the completion of the Pre-operation Testing Steering Test.

To determine if this low pressure warning is caused by operational events. Follow the below procedure:

1. Turn key switch to the OFF position

2. Wait at least two (2) minutes
3. Turn keyswitch ON but do not start the engine

a. If the Low Accumulator Precharge Pressure warning is not active, the truck can be started and put into service.
b. If the Low Accumlator Precharge Pressure Warning remains active. Do not operate truck and follow further
troubleshooting steps below.

4. Temperature variation can affect the precharge pressure of an accumulator. As the temperature increases, the pre-charge
pressure increases. Conversely, decreasing temperature will decrease the precharge pressure. In order to insure the accuracy
of the accumulator precharge pressure, the temperature variation must be accounted for. A temperature variation factor is
determined by the ambient temperature encountered at the time when charging the accumulator on a truck that has been
shut down for one hour. Refer to below table for charging pressures in different ambient operating conditions that the truck is
currently exposed to DURING the charging procedure.

CONFIDENTIAL © 2018 Komatsu LTD. and/or one or more of its affiliates. All rights reserved.
 Remote Monitoring & Diagnostics
Troubleshooting and Repair Recommendation

5. If fault remains active follow the procedure from the shop manual to correctly charge the accumulator.
If the fault remains active after charging accumulator please follow the additional steps below.
6. Inspect for leaking pressure switches and repair/replace if necessary.
7. Check continuity of each pressure switch with accumulators in charged condition. Should be less than 0.5 ohm. Replace if
out of specification.
8. Check continuity of the ground wire '0' at the switches to frame. Should be less than 0.5 ohm. Check and repair circuit back
to the ground block GB31 in the 24 volt auxiliary cabinet if out of specification.

9. Check continuity of link wire between pressure switches. Should be less than 0.5 ohm. Repair or replace if required.
10. Check continuity of wire 51A1 at IM2W to ground. Should be less than 0.5 ohm. Repair if required.
11. With wire 51A1 disconnected at the pressure switch, with key "ON" there should be a floating voltage on the wire
between 1 to 15 volts. If not present, the IM could be faulty.
12. Inspect accumulator and piping for leaks replace any leaking parts

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Remote Monitoring & Diagnostics

Troubleshooting and Repair Recommendation

HOIST CYL (3 STAGE)

1st STAGE 384.2 mm X 358.7 mm X 945.9 mm
2nd STAGE 320.7 mm X 288.8 mm X 945.9 mm
A 3rd STADE 257.1 mm X 193.7 mm X 945.9 mm A
NOTE: 27,628 CU. IN. TOTAL VOLUME TO EXTEND CYLINDERS
STEERING CYL 190.5 mm X 95.3 mm X 665.7 mm
FROM INSTALLED LENGTH (3" CHROME SHOWING) TO FULL
EXTENSION
HEAD

STEERING CYLINDER MANIFOLD

ROD

QUICK DISCONNECT
TEST PORT "TR" SHOCK VALVES
FOR DUMPING
3480 145 PSI
DISABLED TRUCK
(CYLINDER HEAD END)
CAVITY PLUG
CL CR

COUNTERBALANCE VALVE
TEST PORT "TCBV"
4.5:1 PILOT RATIO

OVERCENTER MANIFOLD
FLOW AMP
10:1 AMPLIFICATION
FACTOR L
NEEDLE VALVE R
B QUICK DISCONNECT B
CLOSED FOR ADJUSTMENT ONLY.
OPEN FOR TRUCK OPERATION. FOR DUMPING R L
TO ACC TAP
DISABLED TRUCK 1100 PSI
MANIFOLD
(CYLINDER ROD END) FALLING
(TYP)
P

PILOT VENT STEERING VALVE

ACCUMULATOR
PLUGGED FOR TRUCK OPERATION. 800cc/REV
1400 PSI
OPEN FOR ADJUSTMENT ONLY. NITROGEN PRECHARGE
16.5 GAL (TYP) 2300 PSI
HOIST PILOT VALVE FALLING
ACC1

TEST PORT "TPD" P.P. PORT

PLUGGED P T LS
HOIST VALVE
TEST PORT "TPU" 2750 PSI HOIST E.F. PORT
TEST PORT (PLUGGED)
RELIEF PRESSURE POWER DOWN RELIEF T
"TP2"
TEST PORT "TCBVP" 1500 PSI

LS

ACCUM BLD DWN SWITCH PORT

HP 3000 PSI HT
ACTUATION: 300 15 PSIG (RISING)
C PRESSURE FEEDBACK RESET: 45 PSIG MAX. BELOW ACTUATION
C
2550 PSI
STRG SUPPLY
FALLING
HIGH PRESSURE
FILTER (HOIST)
TO BRAKE MANIFOLD

ACC2
TEST PORT
"TP3"
HIGH PRESSURE PRESSURE
FILTER SENSOR

SP BRAKE
(STEERING) LOCATED IN BRAKE
PORT "TP1" PORT
APU PS
TP4 QD SUPPLY

SHUTTER
SP PR

PANTO
PORT FOR OPTIONAL
PRESSURE SENSOR PRESSURE SENSOR
QUICK DISCONNECT
PUMP FOR DISABLED TRUCK
STEERING SUPPLY

PUMP SPECIFICATIONS
4000 PSI
C-4 10 WT. OIL@ 120 F

STRG RETURN
35 5 PSID SWITCH 0 PSI INLET PRESSURE
HPD TP9
TYP PUMP THEO FLOW DELIVERY
D HPU
B/D VALVE
NO.
STYLE
@ 1900 RPM/@100 PSI @ 2500 PSI D
GEAR PUMP
P1 135 GPM 123 GPM
PUMP PORT "GPA" 16.38 IN 3 /REV
TANK
GEAR PUMP
P2 135 GPM 123 GPM
16.38 IN 3 /REV
TP10 PISTON PUMP
P3 75 GMP 67 GPM
STEERING PUMP 9.15 IN 3 /REV
600 PSI
WITH UNLOADER
VALVE
P1 P2 P3 RELOAD
3225 25 PSI
50 PSID BYPASS UNLOAD
TP8 TP7 TP6 TP5
TYP BLEEDOWN
3525 PSI MAX SPARE RETURN
MANIFOLD
BODY LIMIT LUBE
HOIST PUMPS
CASE VALVE HOIST PILOT RETURN
HIGH PRESSURE FILTER (HOIST) DRAIN
HPPD QD RETURN
HYD PORT FOR OPTIONAL
HPPU
TANK QUICK DISCONNECT
FOR DISABLED TRUCK
STEERING RETURN

ATMOSPHERIC BREATHERS

E E
TREADLE VALVE AND BRAKE MANIFOLD RETURN FROM BRAKE CABINET
RELAY VALVE PORT T RETURN FROM AXLE BOX

TEMPERATURE DIFFUSERS
SENSOR
BAFFLE

BRAKE/HOIST RETURN MANIFOLD

FRONT BRAKES

LOW
LEVEL
SENSOR

INLET STRAINERS
REAR BRAKES
ORIFICE BLOW-OFF VALVE
35 PSI CRACKING
.45 IN DIA (TYP) RETURN FROM ACC TAP LINCOLN LUBE RETURN
MANIFOLD

F F

58B-60-21400-00 AUG 15
STEERING, HOIST & BRAKE COOLING
HYDRAULICS SCHEMATIC
HYD OIL COOLER

WET BRAKE COOLING

OIL RETURN TEMPERATURE 980E-4
CONFIDENTIAL © 2018 Komatsu LTD. and/or one or more of its affiliates. All rights reserved.
A40003 & UP
SENSORS