Komatsu 830E DUMP TRUCK Shop Manual CEBM008601 PDF

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Komatsu 830E DUMP TRUCK Shop Manual CEBM008601 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E DUMP TRUCK Shop Manual CEBM008601 – PDF DOWNLOAD 

Language : English
Pages : 809
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 830E DUMP TRUCK Shop Manual CEBM008601 – PDF DOWNLOAD 

SERIAL NUMBERS

A30650 – A30661
A30663 – A30676

FOREWORD:

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
• This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers
  represent the basic truck model. The letter “E” designates an Electrical propulsion system.
• The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
  (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
  includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 830E DUMP TRUCK Shop Manual CEBM008601 – PDF DOWNLOAD 

SERIAL NUMBERS

A30650 – A30661
A30663 – A30676

COVER 1
FOREWORD 3
TABLE OF CONTENTS 5
SECTION A – GENERAL INFORMATION 7
GENERAL INFORMATION INDEX 7
STANDARD CHARTS AND TABLES 47
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 47
Standard Assembly Torques For 12-Point, Grade 9, Cap Screws (SAE) 48
Standard Metric Assembly Torque For Class 10 9 Cap Screws & Class 10 Nuts 48
Suggested* Sources for Rust Preventive Grease: 48
TABLE XIII COMMON CONVERSION MULTIPLIERS 52
STORAGE AND IDLE MACHINE PREPARATION 53
SHORT TERM IDLE PERIODS 53
PREPARATION FOR STORAGE 54
REMOVAL FROM STORAGE 55
RECONDITIONING AN IDLE VEHICLE 57
ENGINE OPERATION 60
AFTER ENGINE HAS STARTED 61
ENGINE STORAGE-CUMMINS 62
Engine Storage-(Short Term) 62
Prepare the Engine for Short Term Storage 62
Remove the Engine from Short Term Storage 62
Engine Storage- (Long Term) 63
6 Months to 24 Months 63
Prepare the Engine for Long Term Storage 63
Remove the Engine from Long Term Storage 63
ENGINE STORAGE – DETROIT DIESEL 64
Preparing Engine For Storage 64
Extended Storage (more Than 30 Days) 64
Temporary Storage (30 Days Or Less) 64
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE 66
ELECTRIC DRIVE TRUCKS 67
Storage Instructions and Procedures 67
Placing Equipment Into Storage 67
When Storing A Truck That Is Operational 67
When Storing A Truck That Is Not Operational 68
When Storing A Major Component 68
Periodic Inspections 69
Placing Equipment Into Service After Storage 69
When A Truck Is Operational 69
When A Truck Is Not Operational 69
For The First Hour 70
PRESERVATION AND STORAGE ALLISON TRANSMISSION 71
Storage, New Transmission 71
Storage, One Year — Without Oil 71
Storage, One Year With Oil (normally in a vehicle chassis) 71
Restoring Transmission to Service 71
SECTION B – STRUCTURES 73
STRUCTURAL INDEX 73
STRUCTURAL COMPONENTS 75
LADDERS 75
Removal 75
Installation 75
RIGHT HAND DECK 76
Removal 76
Installation 76
CENTER AND LEFT HAND DECK COMPONENTS 77
FUEL TANK 78
Removal 78
Installation 78
SECTION C – ENGINE, FUEL, COOLING AND AIR CLEANER 85
ENGINE, FUEL, COOLING AND AIR CLEANER INDEX 85
POWER MODULE 87
PREPARATION 87
Removal 87
Installation 91
COOLING SYSTEM 93
POWER TRAIN 97
ALTERNATOR REMOVAL PROCEDURE 97
Removal (Komatsu SSDA16V160 or SDA16V160 Engine) 97
ENGINE/ALTERNATOR MATING 99
General Instructions 99
MEASURING PROCEDURE 99
Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine 101
ENGINE 102
Removal 102
Service 102
Installation 102
AIR FILTRATION SYSTEM 103
AIR CLEANER 103
Operation 103
General Service Information 103
MAIN FILTER ELEMENT 103
Removal 103
Installation 104
SAFETY FILTER ELEMENT 105
Removal 105
Installation 105
AIR INTAKE TROUBLESHOOTING 105
AIR CLEANER ASSEMBLY CLEANING 105
Main Filter Cleaning 105
Precleaner Section Cleaning 106
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 109
ELECTRIC SYSTEM (24VDC NON-PROPULSION) INDEX 109
24VDC ELECTRIC SUPPLY SYSTEM 111
ELECTRICAL SYSTEM DESCRIPTION 111
BATTERY 111
Maintenance and Service 111
Troubleshooting 111
BATTERY CHARGING SYSTEM (Niehoff) 113
General Description 113
TROUBLESHOOTING PROCEDURES (On-Truck) 113
Preliminary Checks 114
Test Setup 114
Test Procedure 114
Regulator Bypass Test 115
ON VEHICLE TROUBLESHOOTING GUIDE – SELF ENERGIZED ALTERNATOR 116
ALTERNATOR ELECTRICAL CONDITION – Low Voltage – High Voltage – No Voltage 116
PRELIMINARY PROCEDURES 116
LOW VOLTAGE OUTPUT 116
HIGH VOLTAGE OUTPUT 116
NO VOLTAGE OUTPUT 116
TOOLS AND EQUIPMENT: 116
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 116
Low Maintenance Types: 116
Maintenance Free types: 117
High-Cycle Maintenance Free Types: 117
DEFINITIONS 117
ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized 118
NO ALTERNATOR OUTPUT 118
STATIC TEST – ENGINE OFF, KEY ON, BATTERY SWITCH ON 118
GO TO ALTERNATOR” 118
GO TO “R” TERMINAL ON ALTERNATOR 118
RE-TEST CHARGING CIRCUIT FOR OPERATION with ENGINE RUNNING 118
GO TO REGULATOR (IF REQUIRED) 119
GO TO REGULATOR CONNECTOR ON ALTERNATOR 119
24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE) 120
OPERATION 120
Pressure Switch 121
Check Valve 121
Timer Solenoid 121
MAINTENANCE 121
Prelube System Operation Checks 121
Check Valve 121
Timer Solenoid 121
Troubleshooting Prelube Starter Circuit 122
24 VDC ELECTRIC START SYSTEM 124
CRANKING MOTORS 124
OPERATION 124
Removal 124
Installation 124
CRANKING MOTOR TROUBLESHOOTING 125
Preliminary Inspection 125
No-Load Test 125
Interpreting Results of Tests 125
Disassembly 126
Cleaning and Inspection 128
Armature Servicing 128
Field Coil Checks 128
Field Coil Removal 128
Solenoid Checks 129
Test 129
Assembly 130
Bearing Replacement: 130
Motor Assembly: 130
Pinion Clearance 131
MAGNETIC SWITCH 131
Installation 131
Coil Test 132
24VDC ELECTRICAL SYSTEM COMPONENTS 133
ALARM INDICATING DEVICE (AID) 133
Coolant Level/Flasher Card 133
Temperature/Latch Card 133
Oil Level Card 134
Temperature Card 134
Hot Switch Inverter Card (Slot 4) 134
Hot Switch Inverter Card (Slot 3) 134
Diode Matrix Without Sound Card 134
Diode Matrix With Sound Card 134
BODY-UP SWITCH 134
Adjustment 135
Service 135
HOIST LIMIT SWITCH 135
Adjustment 135
Service 135
BATTERY EQUALIZER 136
Troubleshooting 136
GROUND LEVEL SHUTDOWN 136
24 VOLT RELAY AND DIODE BOARDS 137
RELAY BOARDS 137
Description 137
SERVICE 138
RELAY BOARD COMPONENTS 139
Relay Board 1 Turn Signal 139
Relay Board 2 Payload Meter (Optional) 139
Relay Board 3 Stop Lights 140
Relay Board 4 Parking Brake 140
Relay Board 5 Head Lights 140
Relay Board 6 Auxiliary Panel 141
DIODE BOARD 1 142
Diode Testing 142
CIRCUIT BREAKERS 142
SECTION E – ELECTRICAL PROPULSION AND CONTROL 147
ELECTRIC PROPULSION AND CONTROL INDEX 147
ELECTRICAL PROPULSION COMPONENTS 151
GENERAL SYSTEM DESCRIPTION 151
CONTROL SYSTEM 151
System Operation 152
FL275 Panel 153
CARD REPLACEMENT 154
Removal 154
Installation 154
Card Repair 154
Panel Wiring 154
COMPUTER DESCRIPTION 155
Microprocessor 155
Download Capability 155
SOFTWARE 155
Base Monitor Program 155
Runtime Monitor Program – OBJ Running Code 155
Configuration Software – CFG 156
PTU – Portable Test Unit Code 156
System Regulation 156
Propulsion 157
Retarding 157
TWO-DIGIT DISPLAY PANEL 158
The Coded Number 158
Events 158
Frames 159
Windows 159
System Categories 159
Limits On Resetting Faults 159
NA Faults 160
Event Sequence 160
Resetting Events 160
Event Descriptions 160
Subcode Descriptions 160
2-DIGIT DISPLAY PANEL SUBCODES 168
PORTABLE TEST UNIT (PTU) 171
DESCRIPTION 171
Operational Hints 171
SOFTWARE INSTALLATION PREPARATION 172
HARD DISK SPACE REQUIREMENTS 172
SOFTWARE INSTALLATION ON PTU 172
PTU/Truck Communication Problems 173
THE MAIN MENU 174
Quit Menu 174
PTU Talk To Truck 174
View PTU Saved Files 174
List Stat Data Files 174
Truck Setup (CFG) 174
Select Truck Setup 174
Update CFG Version 174
Change PTU Password 174
CONFIGURATION (CFG) FILE CONVERSION 176
Conversion Procedure 176
Convert Old CFG files for New software 177
STATEX CONFIGURATION FILES 180
0) Source Directory: 180
1) Select A Truck Configuration 181
3) Change/View Serial and Model Numbers 183
2) View Truck Configuration: Data Curves 182
4) View Options 183
5) Change/View Truck Specifics 185
6) Change/View Overspeeds 187
7) Save a Truck Configuration, filename: 188
8) Save Directory: 189
CHANGE PTU PASSWORD 190
PROGRAMMING THE TRUCK 191
Connect PTU to the Truck 191
Select Configuration File 191
Activate The PTU Mode 191
Check Object Code Version 192
Download Configuration Files 193
Date And Time 194
Event Data 195
Statistical Data 197
View Counters 197
View Profiles 197
Upload Statistical Data To A File 197
Statistical Data Codes – Counters 198
STATISTICAL DATA CODES – COUNTERS 199
STATISTICAL DATA CODES – PROFILES 204
TRUCK SPECIFIC INFORMATION 208
Temporary Truck Settings 209
MISCELLANEOUS FEATURES 210
Saving Data 210
PTU Abbreviations 211
Other Menu Selections 211
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 212
ALTERNATOR 212
ELECTRIC WHEEL MOTORS 212
RETARDING GRIDS 212
ELECTRONIC ACCELERATOR AND RETARD PEDALS 212
Removal 212
Installation 212
Disassembly 213
Reassembly 213
COOLING BLOWER WARNING SYSTEM 213
Operation 213
Test 213
Removal 214
Installation 214
ELECTRICAL CONTROL CABINET 215
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 220
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 221
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 227
GENERAL INFORMATION 227
COMMUNICATIONS PORT CHECK 228
PTU Hookup 228
4 0 SEQUENCE TESTS – (ENGINE NOT ON) 229
Preparation and Setup 229
CONTROL SYSTEM SELF-TEST 230
4 1 THROTTLE SYSTEM CHECK AND ADJUSTMENT 230
4 2 RETARD SYSTEM CHECK AND ADJUSTMENT 231
PTU Setup 231
4 3 REVERSER AND PROPULSION CONTACTORS CHECK 232
4 4 NOT USED 233
4 5 RETARD CONTACTORS OPERATION CHECK 233
4 6 GROUND FAULT SENSING CHECK 233
4 7 GROUND FAULT IN RETARD OPERATION CHECK 234
4 8 OVERRIDE OPERATION CHECK 234
4 9 ANTI-REVERSAL FUNCTION (AR) CHECK 235
4 10 OVERSPEED RETARD OPERATION CHECK 235
4 11 HOIST INTERLOCK OPERATION CHECK 236
4 12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK 236
Return to Main Menu 236
5 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 237
5 1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU 237
5 2 DIGITAL INPUT CHECKS 238
5 3 DIGITAL OUTPUT CHECKS 239
6 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 243
6 1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU 243
6 2 ANALOG INPUT CHECKS 244
6 3 FREQUENCY INPUT CHECKS 248
Return to Main Menu 249
7 0 SPEED EVENT CHECKS 249
Preparation and Setup 249
Setup PTU 249
7 1 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK 250
7 2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK 250
7 3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK 250
7 4 OTHER SPEED EVENTS CHECKS 250
Return to Main Menu 250
8 0 RETARD SPEED CONTROL SYSTEM CHECK 251
Preparation and Setup 251
Setup PTU 251
8 1 OVERSPEED PICKUP AND DROPOUT CHECK 251
8 2 RETARD POT MAXIMUM SETTING CHECK 251
8 3 RETARD POT MINIMUM SETTING CHECK 251
8 4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL 252
Return to Main Menu 252
9 0 LOAD TEST USING TRUCK RETARD GRIDS 252
Setup and Preparation 252
PTU Setup 252
9 1 LOAD TEST 253
10 0 MOTOR FIELD CURRENT CHECK IN RETARDING 253
Setup PTU 253
10 1 RETARD CHECK 254
11 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 255
11 1 BRAKE SYSTEM INTERLOCKS CHECK 255
Preparation 255
11 2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT 255
11 3 SYNC TRANSFORMER CHECKOUT 256
11 4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT 256
11 5 BATTERY BOOST ADJUSTMENT 256
11 6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST 256
11 7 MOTOR ROTATION TEST 257
11 8 GROUND FAULT CHECKS 257
12 0 MISCELLANEOUS CHARTS 258
12 1 WHEEL MOTOR GEAR RATIOS 258
12 2 MAXIMUM ALLOWABLE TRUCK SPEEDS 259
12 3 ENGINE OPTIONS 260
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE TABLE OF CONTENTS 261
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS 263
DRIVE AXLE, SPINDLE AND WHEELS INDEX 263
TIRES AND RIMS 265
FRONT TIRES AND RIMS 265
Removal 265
Installation 266
REAR TIRES AND RIMS 267
Removal 267
Installation 268
RIM 269
Tire Removal 269
RIM AND TIRE PREPARATION 269
LUBRICANTS 270
TIRE INSTALLATION 270
FRONT WHEEL HUB AND SPINDLE 273
WHEEL HUB AND SPINDLE ASSEMBLY 273
Removal 273
Spindle Pusher Tool Usage 274
Installation 275
Disassembly 277
Cleaning and Inspection 277
Assembly 278
Wheel Bearing Adjustment (Tire Removed) 280
Wheel Bearing Adjustment (Tire mounted) 280
STEERING CYLINDERS AND TIE ROD 282
Spherical Bearing Wear Limits 282
Removal 283
Installation 283
Bearing Replacement 283
TOE-IN ADJUSTMENT 285
REAR AXLE HOUSING ATTACHMENT 287
PIVOT PIN 287
Removal 287
Installation 287
PIVOT EYE BEARING 288
Disassembly 288
Assembly 288
PIVOT EYE REPAIR 289
Removal 289
Disassembly 289
Assembly 289
Installation 289
ANTI-SWAY BAR 290
Removal 290
Installation 290
Disassembly 290
Assembly 290
Cleaning and Inspection 290
REAR AXLE HOUSING 291
REAR AXLE HOUSING 291
Removal 291
Installation 291
WHEEL MOTOR 291
Removal 291
Cleaning and Inspection 292
Installation 292
Maximum Cap Screw Usage 292
SECTION H – HYDRAIR II SUSPENSIONS 293
HYDRAIR® II SUSPENSIONS INDEX 293
FRONT SUSPENSION 295
Removal 295
Installation 296
MAXIMUM CAP SCREW USAGE 297
“TURN-OF-THE-NUT” Tightening Procedure 298
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 299
Bearing Structure Removal 299
Bearing Structure Installation 299
MAJOR SUSPENSION REBUILD 300
Disassembly 300
Assembly 301
PRESSURE TEST 302
REAR SUSPENSIONS 303
Removal 303
Installation 305
Disassembly 307
Cleaning and Inspection 307
Assembly 307
PRESSURE TEST 308
OILING AND CHARGING PROCEDURE 309
GENERAL 309
EQUIPMENT LIST 309
HYDRAIR® CHARGING KIT 309
Installation of Charging Kit 309
Removal of Charging Kit 310
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 310
FRONT SUSPENSION 311
Front Suspension Oiling 311
Front Suspension Nitrogen Charging 312
REAR SUSPENSION 313
Rear Suspension Oiling 313
Rear Suspension Nitrogen Charging 314
OIL AND NITROGEN SPECIFICATIONS CHART 316
SECTION J – BRAKE CIRCUIT 317
BRAKE CIRCUIT INDEX 317
BRAKE CIRCUIT COMPONENT SERVICE 325
BRAKE VALVE 325
Rebuild Criteria 325
Removal 325
DISASSEMBLY 328
Cleaning and Inspection 330
ASSEMBLY 330
Actuator Base Threaded Inserts 330
Boot and Cap 330
Valve Body Seal Installation 331
Regulator Sleeve O-Ring Installation 331
Actuator Plunger O-ring Installation 331
Assembly of Valve 332
DIFFERENTIAL PRESSURE SWITCH 333
Disassembly 333
Cleaning and Inspection 333
Assembly 333
VALVE BENCH TEST AND ADJUSTMENT 334
Test Set Up Procedure 335
Brake Valve Output Pressure Adjustment 335
Differential Pressure Switch Test 335
Final Test and Adjustment 336
Installation Of Brake Pedal Actuator Assembly to Brake Valve 337
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal) 338
Installation of Retard Pedal To Brake Pedal 338
HYDRAULIC BRAKE ACCUMULATORS 339
Brake Accumulator Bleed Down Procedure 339
Removal 339
Installation 339
Disassembly 339
Cleaning and Inspection 340
Assembly 341
Charging Procedure 342
BRAKE MANIFOLD 343
Removal 343
Removal 343
Installation 344
Disassembly 344
Cleaning and Inspection 344
Assembly 344
BRAKE CIRCUIT CHECK-OUT PROCEDURE 345
EQUIPMENT REQUIRED 347
INITIAL SYSTEM SET-UP 348
PARKING BRAKE 348
BRAKE SYSTEM CHECK-OUT 348
Failure Modes Check-Out 349
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 351
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 355
KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET 356
ROCKWELL WHEEL SPEED FRONT DISC BRAKES 357
BRAKE CALIPER 357
Caliper Removal 357
Installation 358
Disassembly 359
Assembly 359
Cleaning and Inspection 360
BRAKE LINING 361
Replacement 361
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 362
SAFETY PRECAUTIONS 362
FRONT BRAKE CONDITIONING 362
BRAKE BLEEDING PROCEDURES 364
ROCKWELL ARMATURE SPEED REAR DISC BRAKES 365
REAR BRAKES 365
CALIPER, DISC, AND PARKING BRAKE 365
Caliper, Disc, and Parking Brake Removal 365
Caliper, Disc, And Parking Brake Installation 366
CALIPER, DISC, & PARKING BRAKE REMOVAL [For trucks equipped with one-piece adapter (16, Figure 6-3A)] 368
Caliper, Disc, And Parking Brake Installation 369
CALIPER PISTON 370
Piston Assembly Removal 370
Inspection 370
Piston Assembly Installation 370
FUNCTIONAL TEST OF PISTON ASSEMBLY 371
Return Spring Force 371
Built-In Clearance 371
Grip Force 372
Grip Force Measurement 373
Spring Force Measurement 374
Disassembly of Piston Assembly 375
Assembly of Piston Assembly 376
BENCH TEST 376
BRAKE LINING 377
Replacement 377
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 380
General 380
Safety Precautions 380
Rear Brake Conditioning 381
BRAKE BLEEDING PROCEDURE 382
ROCKWELL DISC PARKING BRAKE 383
PARK BRAKE CALIPER 383
Removal 383
Installation 384
Parking Brake Adjustment 384
Park Brake Caliper Disassembly 386
Cleaning and Inspection 386
Park Brake Caliper Assembly 387
PARK BRAKE LINING REPLACEMENT 388
PARK BRAKE BURNISH PROCEDURE 388
Lining Conditioning 388
BRAKE BLEEDING PROCEDURE 388
SECTION L – HYDRAULIC SYSTEM 389
HYDRAULIC SYSTEM INDEX 389
HYDRAULIC SYSTEM 391
HYDRAULIC SYSTEM OPERATION 391
COMPONENT DESCRIPTION 392
HYDRAULIC SYSTEM COMPONENT REPAIR 395
HOIST PUMP 395
Removal 395
Installation 396
Disassembly 397
INSPECTION OF PARTS 400
Assembly 401
HYDRAULIC TANK 406
Filling Instructions 406
Removal 406
Installation 407
HYDRAULIC TANK STRAINERS 407
Removal 407
Inspect and Clean 407
Installation 407
HYDRAULIC TANK BREATHERS 408
HOIST CIRCUIT FILTERS 408
FILTER ELEMENT REPLACEMENT 409
Removal 409
INDICATOR SWITCH 409
STEERING CIRCUIT 411
STEERING CIRCUIT OPERATION 411
COMPONENT DESCRIPTION 412
STEERING CONTROL UNIT 412
FLOW AMPLIFIER 412
No Steer 414
Steering Left 416
Steering Right 418
No Steer, External Shock Load 420
BLEED DOWN MANIFOLD 422
ACCUMULATORS 423
Low Precharge Warning Switch 423
HIGH PRESSURE FILTER 423
STEERING/BRAKE PUMP 423
Operation 424
PRINCIPLE OF OPERATION 426
Full Pump Volume: 426
Half Pump Volume: 426
STEERING CIRCUIT COMPONENT REPAIR 429
BLEED DOWN MANIFOLD 429
Removal 429
Installation 429
ACCUMULATOR 430
Removal 430
Installation 431
Disassembly 432
Cleaning and Inspection 432
Assembly 433
TESTING 433
FLOW AMPLIFIER 435
Removal 435
Installation 435
Disassembly 436
Reassembly 439
STEERING CONTROL UNIT 440
Removal 440
Spline Inspection 440
Installation 440
Disassembly 441
Cleaning and Inspection 442
Assembly 442
STEERING CYLINDER 446
Disassembly 446
Inspection and Cleaning 446
Assembly 446
STEERING CIRCUIT FILTER 447
FILTER ELEMENT REPLACEMENT 447
Removal 448
Installation 448
INDICATOR SWITCH 448
STEERING AND BRAKE PUMP 449
Removal 449
Installation 449
Disassembly 451
Control Piston Group 451
Valve Plate Group 451
Rotating Group 452
Swashblock Group 452
Driveshaft Group 452
INSPECTION 452
Control Piston Group 452
Rotating Group 452
Valve Plate Group 452
Swashblock Group 456
Driveshaft Group 456
Compensator Block and Unloader Module 456
Stroke Adjuster Assembly 456
ASSEMBLY 456
Swashblock Group 456
Control Piston Group 458
Valve Plate Group 458
HOIST CIRCUIT 461
HOIST CIRCUIT OPERATION 461
COMPONENT DESCRIPTION 462
HOIST VALVE 463
HOIST PILOT VALVE 464
HOIST-UP LIMIT SOLENOID 464
PILOT OPERATED CHECK VALVE 464
COUNTERBALANCE VALVE MANIFOLD 464
HOIST SYSTEM OPERATION MODES 390
FLOAT POSITION OF PILOT VALVE AND BODY ON FRAME (Figure 7-6) 466
POWER UP OPERATION (Figure 7-7) 468
HOLD OPERATION (Figure 7-8) 470
POWER DOWN OPERATION (Figure 7-9) 472
FLOAT OPERATION (Figure 7-10) 474
HOIST CIRCUIT COMPONENT REPAIR 477
HOIST VALVE 477
Removal 477
Installation 477
O-Ring Replacement 478
INLET SECTION 478
Disassembly 478
Cleaning and Inspection 479
Assembly 480
SPOOL SECTION 480
Disassembly 480
Cleaning and Inspection 482
Assembly 482
HOIST PILOT VALVE 483
Removal 483
Installation 483
Disassembly 483
Cleaning and Inspection 485
Assembly 485
BODY UP LIMIT SOLENOID 486
PILOT OPERATED CHECK VALVE 486
HOIST CYLINDERS 486
Removal 486
Installation 487
Disassembly 489
Cleaning and Inspection 490
ASSEMBLY OF QUILL AND CYLINDER 491
Quill Installation 491
Installation of Check Balls and Plugs in Quill 492
Assembly of Cylinder 493
COUNTERBALANCE MANIFOLD 494
The counterbalance manifold is located to the rear of the hoist valve The internal counterbalance valve relieves excessive pres 494
DISABLED TRUCK DUMPING PROCEDURE 495
HOOKUP 495
DUMPING PROCEDURE 495
HYDRAULIC CHECKOUT PROCEDURE 497
STEERING AND BRAKE PUMP 497
Pressure Check And Adjustment Procedure 497
BLEEDDOWN MANIFOLD 498
SHOCK & SUCTION VALVES 499
Shock & Suction Valve Settings 499
LEAKAGE TESTS 500
Steering Control Unit & Flow Amplifier 500
Bleeddown Manifold 500
ACCUMULATOR BLEED DOWN PROCEDURE 501
LOW STEERING PRESSURE SWITCH 501
CHECKING HOIST SYSTEM PRESSURES 508
Hoist System Relief Pressure Adjustment 508
Power Down Relief Pressure Adjustment 509
Hoist Counterbalance Valve Adjustment 510
Preparation: 510
Counterbalance Valve Pressure Check Only: 510
Counterbalance Valve Adjustment 511
HYDRAULIC SYSTEM FLUSHING PROCEDURE 514
OIL CLEANLINESS CHECK 515
SECTION M – OPTIONS AND SPECIAL TOOLS 517
OPTIONS AND SPECIAL TOOLS INDEX 517
FIRE CONTROL SYSTEM (MANUAL) 519
Operation 519
Inspection and Maintenance 519
Recharging Procedures 520
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM 521
SYSTEM ADJUSTMENT 521
PUMP 521
Removal 521
Disassembly 521
Inspection 523
Assembly 523
Installation 524
BLOWER DRIVE MOTOR 524
Removal 525
Disassembly 525
Inspection Of Parts 526
Assembly 526
Installation 527
BLOWER BEARING REPAIR 527
Removal 527
Replacement 527
Assembly 528
AIR CLEANER 528
Assembly 528
Removal 528
Washing Air Cleaner 528
Assembly 528
WIGGINS QUICK FILL FUEL SYSTEM 529
FUEL RECEIVER 529
TANK BREATHER VALVE 530
Removal 530
Installation 530
Disassembly 530
Assembly 530
LEFT SIDE FILL 531
BUCKEYE QUICK FUEL SYSTEM 533
FUEL TANK BREATHER VALVE 533
Maintenance 533
Filter Service 533
Disassembly 533
Inspection 533
Assembly 533
FUEL RECEIVER 534
ENGINE COOLANT HEATER 535
Maintenance 535
HEATING ELEMENT 535
Removal 535
Installation 535
THERMOSTAT 536
Removal 536
Installation 536
SPECIAL TOOLS 537
AIR CONDITIONING SYSTEM 543
Environmental Impact 543
OPERATOR CAB AIR CONDITIONING 544
PRINCIPLES OF REFRIGERATION 544
Air Conditioning 544
Refrigeration – The Act Of Cooling 545
The Refrigeration Cycle 545
AIR CONDITIONER SYSTEM COMPONENTS 546
Compressor (Refrigerant Pump) 546
Service Valves 546
Condenser 546
Expansion Block Valve 547
Evaporator 547
ELECTRICAL CIRCUIT 548
Thermostat 548
Compressor Clutch 548
Trinary™ Switch 549
SYSTEM SERVICING 550
SYSTEM OIL 551
Handling and Reusing PAG Oil 551
Oil Quantity 551
Replacing Oil After Servicing the System 551
Setting Up a New Compressor 551
REFRIGERANT 552
Recycled Refrigerant 552
Reclaimed Refrigerant 552
Refrigerant Quantity 552
R-134a Refrigerant Containers 552
SERVICE TOOLS AND EQUIPMENT 553
Recovery/Recycle Station 553
Leak Detector 553
Service Valves 554
Vacuum Pump 554
Manifold Gauge Set 555
Installing Manifold Gauge Set 556
Purging Air From Service Hoses 557
Stabilizing the AC System 558
SYSTEM PERFORMANCE TEST 558
SYSTEM LEAK TESTING 559
Electronic leak detector 559
Tracer dyes 559
Soap and water 559
SYSTEM REPAIR 560
System Cleaning 560
Hoses and Fittings 560
Lines 560
Expansion Valve 560
Receiver-Drier 561
Thermostat 561
Compressor 561
Clutch 561
Servicing the Compressor Clutch 562
Pulley Removal 564
Clutch Coil Check 564
Pulley Installation 564
Clutch Assembly Installation 565
RECOVERING AND RECYCLING THE REFRIGERANT 566
Performing the Recovery Cycle 566
Performing the Recycling Procedure 566
Evacuating and Charging the AC System 566
EVACUATING THE SYSTEM 567
CHARGING THE AC SYSTEM 568
TROUBLESHOOTING 569
Pre-Diagnosis Checks 569
Preparing For Diagnosis 569
Preliminary Steps 569
System Performance Test 569
Diagnosis Of Gauge Readings And System Performance 570
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 577
RADIATOR SHUTTERS 579
OPERATION 579
Hydraulic Circuit 579
Electrical Circuit: 580
MAINTENANCE AND REPAIR 580
TROUBLESHOOTING 582
Hydraulic Troubleshooting 585
Electrical Troubleshooting 587
Electrical troubleshooting 588
SECTION M20 PAYLOAD METER III ™ INDEX 591
OPERATION SECTION 595
Introduction 595
Data Summary 595
Data Gathering 595
COMPONENT DESCRIPTION 596
System Diagram 596
Inclinometer 596
Suspension Pressure Sensors 596
Operator Display 596
Operator Switch 597
Speed Input 597
Body-Up Switch 597
Brake Lock Switch 597
Payload Meter 597
Communications Ports 597
Key Switch Input 598
Payload Meter Power 598
Load Lights 598
Wiring and Termination 599
TCI Outputs 599
OPERATOR’S DISPLAY AND SWITCH 600
Reading the Speedometer 600
Reading the Load Display 600
Using the Operator ID 600
Using the Load and Ton Counter 600
Total Ton Counter 600
Total Load Counter 601
Clearing the Counters 601
Viewing Live Sensor Data 601
Other Display Messages 601
PAYLOAD OPERATION & CALCULATION 602
Description of Haul Cycle States 602
Haul Cycle Description 602
Load Calculation 603
Carry Back 603
Measurement Accuracy 603
SOURCES FOR PAYLOAD ERROR 603
Payload Error 603
Loading Conditions 604
Pressure Sensors 604
Swingloads 604
Speed and Distance 604
HAUL CYCLE DATA 604
Haul Cycle Warning Flags 606
Frame Torque Data 607
Sprung Weight Data 607
Maximum Speed Data 607
Alarm Records 607
Fault Code Data 608
PC SOFTWARE OVERVIEW 609
System Configuration 609
Installing the PLMIII Software 609
DOWNLOADING DATA 610
PLM III SYSTEM CONFIGURATION 611
Starting Communications 611
Displayed Payload Units 611
Time Units 611
Connection Menu 611
Connecting to the Payload Meter 612
Configure the Payload Meter 612
Setting the Date and Time 612
Setting the Truck Type 613
Setting the Gauge Display Units 613
Setting the Frame Serial Number 613
Setting the Truck Number 613
Setting the Komatsu Distributor 613
Setting the Komatsu Customer 613
Clean Truck Tare 614
Inclinometer Calibration 614
DATA ANALYSIS 615
Creating a Query 615
Sorting on Truck Unit Number 615
Sorting on Truck Type 615
Sorting on Date Range 616
Sorting on Time Range 616
Payload Detail Screen 617
Creating Reports 617
Summary – one page report 618
Detailed – multi-page report 618
Creating Graphs 619
Exporting Data 619
CSV Export 619
Compressed 620
Importing Data 621
Deleting Haul Cycle Records 621
Viewing Alarms 622
Deleting Alarm Records 622
TROUBLESHOOTING SECTION 623
TROUBLESHOOTING 623
Viewing Active Alarms 623
Real-Time Data Display 623
Testing the Payload Lights 623
Creating Log Files of Inputs 624
Daily Inspections 624
Periodic Maintenance 624
Abnormal Displays at Power-Up 625
No Payload Display When Key Switch is Turned ON 626
No Display on Speedometer 627
No Display on Operator Display 627
No Communications With PC 628
Load Lights Don’t Light During Loading 629
Load Lights Remain ON 630
Load Lights Remain ON During Dumping 630
Display Doesn’t Clear When The Load Is Dumped 630
Calibration Problems 631
Alarm 1 – Left Front Pressure High 632
Alarm 2 – Left Front Pressure Low 632
Troubleshoot Wiring to Left Front Suspension 632
Alarm 3 – Right Front Pressure High 633
Alarm 4 – Right Front Pressure Low 633
Troubleshoot Wiring to Right Front Suspension 633
Alarm 5 -Left Rear Pressure High 634
Alarm 6 – Left Rear Pressure Low 634
Troubleshoot Wiring to Left Rear Suspension 634
Alarm 7 – Right Rear Pressure High 635
Alarm 8 – Right Rear Pressure Low 635
Troubleshoot Wiring to Right Rear Suspension 635
Alarm 9 – Inclinometer High 636
Alarm 10 – Inclinometer Low 636
Troubleshoot Inclinometer Wiring 636
Alarm 13 – Body Up Input Failure 637
Alarm 16 – Memory Write Failure 638
Alarm 17 – Memory Read Failure 638
Alarm 18 639
Alarm 19 639
Alarm 22 639
Operator Switch Doesn’t Work 640
Alarm 26 – User Switch Fault – SELECT 640
Alarm 27 – User Switch Fault – SET 640
Connector Map 641
Connectors 642
PLMIII CHECK OUT PROCEDURE 643
General Description 643
Tools Required 643
Checkout Procedure 643
PLMIII CHECKOUT PROCEDURE CONFIRMATION 647
Flashburn Programming 647
Confirmation Checklist 649
RESERVE ENGINE OIL SYSTEM 651
Extend oil change intervals 651
Operation 652
LED Monitor Light 652
Tank Fill Control (Optional) 653
Service 654
Changing Oil 654
TROUBLESHOOTING 655
System Electrical Schematics 656
SECTION N – OPERATOR’S CAB 657
OPERATOR’S CAB INDEX 657
TRUCK CAB 659
CAB DOOR 662
Removal 662
Installation 662
Door Adjustment 662
Door Jamb Bolt Adjustment 662
Door Handle Plunger Adjustment 664
Replace Door Glass 665
Replace Door Window Regulator 669
Replace Door Handle or Latch Assembly 669
Door and Door Hinge Seal Replacement 670
Door Opening Seal Removal 670
Installation 670
GLASS REPLACEMENT 671
ADHESIVE-BONDED WINDOWS 671
Replacement Procedure 671
WINDSHIELD & REAR GLASS 672
Removal 672
Installation 673
Description 659
Removal 660
Installation 661
CAB COMPONENTS 675
WINDSHIELD WIPER 675
Removal 675
Installation 675
WINDSHIELD WASHER 676
Operation 676
Service 676
OPERATOR COMFORT 677
OPERATOR SEAT 677
Adjustment 677
Removal 677
Installation 677
HEATER/AIR CONDITIONER CONTROLS 678
OPERATION 678
HEATER/AIR CONDITIONER 679
OPERATION 679
HEATER COMPONENTS 679
CIRCUIT BREAKERS 679
RELAYS 679
HEATER CORE 680
FAN MOTOR AND SPEED CONTROL 680
Test 680
ACTUATORS 680
Test 680
FILTER 680
Service 680
AIR CONDITIONER COMPONENTS 680
OPERATOR CONTROLS AND EQUIPMENT 683
STEERING WHEEL AND CONTROLS 684
HORN BUTTON 684
TILT / TELESCOPE LEVER 684
TURN SIGNAL / HEADLIGHT DIMMER 684
STEERING COLUMN 684
Removal 684
Spline Inspection 685
Installation 685
SERVICE BRAKE PEDAL 686
DYNAMIC RETARDER PEDAL 686
THROTTLE PEDAL 686
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 687
DEFROSTER VENT CONTROL SWITCH 687
OUTSIDE/INSIDE AIR CONTROL SWITCH 687
HEAT VENT CONTROL SWITCH 687
TEMPERATURE CONTROL KNOB 687
FAN CONTROL KNOB 687
HEATER/AIR CONDITIONER SELECTOR SWITCH 687
HEATER/AIR CONDITIONER VENTS 687
INSTRUMENT PANEL 688
GRADE/SPEED WARNING CHART 688
RADIO SPEAKERS 688
WARNING ALARM BUZZER 688
CAB RADIO 688
WARNING LIGHTS DIMMER CONTROL 688
STATUS / WARNING INDICATOR LIGHT PANEL 688
PAYLOAD METER (NOT SHOWN) 688
WINDSHIELD WIPERS 688
AIR CLEANER VACUUM GAUGES 689
CENTER CONSOLE 689
HOIST CONTROL LEVER 690
ASH TRAY 690
LIGHTER 690
L H WINDOW CONTROL SWITCH 690
R H WINDOW CONTROL SWITCH 690
ENGINE SHUTDOWN SWITCH 690
OVERRIDE SWITCH 691
10, Figure 5-5: BLANK 691
RETARD SPEED CONTROL (RSC) “OFF/ON” SWITCH 691
RETARD SPEED CONTROL (RSC) ADJUST DIAL 691
KOMATSU ENGINE QUANTUM CONNECTOR 692
KOMATSU ENGINE CENSE CONNECTOR 692
STATEX III PROPULSION SYSTEM DIAGNOSTIC CONNECTOR 692
SPARE CONNECTOR LOCATION 692
PASSENGER SEAT 692
INSTRUMENT PANEL AND INDICATOR LIGHTS 693
CONTROL SYMBOLS 693
INSTRUMENT PANEL 694
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 3-6) 695
(1, Figure 5-6) KEY SWITCH 695
(2, Figure 5-6) ENGINE SHUTDOWN SWITCH with TIMER DELAY (OPTIONAL) 695
(3, Figure 5-6) MANUAL BACKUP SWITCH 695
(4, Figure 5-6) LADDER LIGHT SWITCH 695
(5, Figure 5-6) FOG LIGHTS (OPTIONAL) 696
(6, Figure 5-6) PANEL ILLUMINATION LIGHTS 696
(7, Figure 5-6) CAB AIR CONDITIONER / HEATER VENTS 696
(8, Figure 5-6) ENGINE COLD WEATHER STARTING AID (OPTIONAL) 696
(9, Figure 5-6) ROTATING BEACON LIGHT SWITCH (OPTIONAL) 696
(10, Figure 5-6) HEATED MIRROR SWITCH (OPTIONAL) 696
(11, Figure 5-6) BLANK (Not Used In This Application) 696
(12, Figure 5-6) WHEEL BRAKE LOCK CONTROL 696
(13, Figure 5-6) PARKING BRAKE CONTROL 697
(14, Figure 5-6) TACHOMETER 697
(15, Figure 5-6) RIGHT TURN SIGNAL INDICATOR 697
(16, Figure 5-6) HIGH BEAM INDICATOR 697
(17, Figure 5-6) LEFT TURN SIGNAL INDICATOR 697
(18, Figure 5-6) SPEEDOMETER 697
(19, Figure 5-6) VOLTMETER 697
(20, Figure 5-6) ENGINE OIL PRESSURE GAUGE 697
(21, Figure 5-6) WATER TEMPERATURE GAUGE 698
(22, Figure 5-6) FUEL GAUGE 698
(23, Figure 5-6) (Not Used) 698
(24, Figure 5-6) HOURMETER 698
(25, Figure 5-6) (Not Used) 698
(26, Figure 5-6) LIGHT SWITCH 698
(27, Figure 5-6) WINDSHIELD WIPER and WASHER 698
(28, Figure 5-6) PANEL LIGHT DIMMER 698
INDICATOR LIGHT SYMBOLS 700
D1 Electric System Fault 701
E1 Low Brake Pressure 701
A2 Low Hydraulic Tank Level (OPTIONAL) 701
B2 Low Automatic Lubrication System Pressure 701
C2 Circuit Breaker Tripped 701
D2 Hydraulic Oil Filter Monitor 701
E2 Low Fuel 701
A3 Parking Brake 701
B3 Service Brake 702
C3 Body Up 702
D3 Dynamic Retarding 702
E3 Stop Engine 702
A4 NOT USED 702
B4 Manual Backup Lights 703
C5 Motor Blower OFF 704
D5, E5, A6, B6, C6, D6, E6: NOT USED 704
(7) HAZARD WARNING LIGHTS 704
(8) LAMP TEST SWITCH 704
SECTION P – LUBRICATION AND SERVICE 705
LUBRICATION AND SERVICE INDEX 705
MOTORIZED WHEEL MAINTENANCE SCHEDULE 737
AXLE BOX 737
MOTORIZED WHEEL MAINTENANCE SCHEDULE 738
ARMATURE AREA 738
AT TIRE CHANGE – FOR ALL MOTORIZED WHEELS 738
MOTORIZED WHEEL MAINTENANCE SCHEDULE 739
GENERATOR / ALTERNATOR 739
GRID BLOWER MOTOR 739
CONTROL EQUIPMENT CHECKS 739
MOTORIZED WHEEL MAINTENANCE SCHEDULE 740
AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM 740
VEHICLE OPERATIONS TESTS 740
SECTION Q – ALPHABETICAL INDEX 741
SECTION R – SYSTEM SCHEMATICS INDEX 745
HYDRAULIC HOIST/STEERING SCHEMATIC 747
HYDRAULIC BRAKE SCHEMATIC (STATEX III; LAPS) 748
STATEX III FL275 PANEL 749
PANEL CARD LOCATIONS 750
STATEX III FL328 PANEL 751
FB100 POWER SUPPLY CARD 752
FB100 POWER SUPPLY CARD 753
FB101 PROCESSOR CARD 754
FB101 PROCESSOR CARD 755
FB101 PROCESSOR CARD 757
FB140/149 ANALOG I/O CARD 758
FB140/149 ANALOG I/O CARD 759
FB155 DIGITAL I/O CARD 760
FB155 ANALOG I/O CARD/FB104 DIGITAL I/O CARD 761
FB104 DIGITAL I/O CARD 762
FB104 DIGITAL I/O CARD 763
FB103 DIGITAL I/O CARD 764
FB103 DIGITAL I/O CARD 765
FB104 DIGITAL I/O CARD 766
CONNECTOR A 767
CONNECTOR B 1/3 768
CONNECTOR B 2/3 768
CONNECTOR B 3/3 769
CONNECTOR C 1/2 770
CONNECTOR C 2/2 771
CONNECTOR D 1/3 772
CONNECTOR D 2/3 773
CONNECTOR D 3/3 774
CONNECTOR E 1/4 775
CONNECTOR E 2/4 776
CONNECTOR E 3/4 777
CONNECTOR E 4/4 778
INDEX AND SYMBOLS ES0601 SHEET 1 OF 29 779
CIRCUIT NUMBER LOCATOR ES0602 SHEET 2 OF 29 780
COMPONENT LOCATOR ES0603 SHEET 3 OF 29 781
COMPONENT LOCATOR ES0604 SHEET 4 OF 29 782
G E FAULT CODES ES0605 SHEET 5 OF 29 783
G E FAULT CODES ES0606 SHEET 6 OF 29 784
POWER DISTRIBUTION ES0607 SHEET 7 OF 29 785
POWER 18 ELEMENT 3 STEP RETARDING ES0608 SHEET 8 OF 29 786
POWER 18 ELEMENT 3 STEP RETARDING ES0609 SHEET 9 OF 29 787
POWER 20 ELEMENT 7 STEP RETARDING ES0610 SHEET 10 OF 29 788
DRIVE SYSTEM CONTROL CIRCUITS ES0611 SHEET 11 OF 29 789
TWO DIGIT DISPLAY ES0612 SHEET 12 OF 29 790
G E ANALOG INPUTS ES0613 SHEET 13 OF 29 791
G E DIGITAL INPUTS, AUTO LUBE CONTROL / TEST ES0614 SHEET 14 OF 29 792
REAR TAIL LIGHTS, DIMMER CONTROL ES0615 SHEET 15 OF 29 793
5 MINUTE IDLE, SPARE WIRES ES0616 SHEET 16 OF 29 794
WINDOWS, RADIO, GAUGES ES0617 SHEET 17 OF 29 795
CONTRACTOR FEEDBAK ES0618 SHEET 18 OF 29 796
CONTRACTOR COILS ES0619 SHEET 19 OF 29 797
MACHINE CONTROL CIRCUITS ES0620 SHEET 20 OF 29 798
ACCELERATOR, RETARD PEDALS ES0621 SHEET 21 OF 29 799
HYDRAULIC CONTROLS, ALARMS ES0622 SHEET 22 OF 29 800
HEATER / AC, WINDSHIELD WIPER CONTROLS ES0623 SHEET 23 OF 29 801
LIGHT CONTROL CIRCUITS ES0624 SHEET 24 OF 29 802
INSTRUMENT LIGHTS, DIAGNOSTIC PORTS ES0625 SHEET 25 OF 29 803
MOD, MINING DISPATCH ES0626 SHEET 26 OF 29 804
CUMMINS QSK60 ENGINE ES0627 SHEET 27 OF 29 805
CUMMINS QSK60 ENGINE ES0628 SHEET 28 OF 29 806
4000 DDEC ENGINE ES0629 SHEET 29 OF 29 807

S.V 15/12/24