Komatsu 830E Dump Truck Shop Manual CEBM014900 PDF

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Komatsu 830E Dump Truck Shop Manual CEBM014900 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E Dump Truck Shop Manual CEBM014900 – PDF DOWNLOAD 

Language : English
Pages : 823
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 830E Dump Truck Shop Manual CEBM014900 – PDF DOWNLOAD 

SERIAL NUMBERS A30733 – A30815

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 CEBM014900 – PDF DOWNLOAD 

SERIAL NUMBERS A30733 – A30815

MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
GENERAL INFORMATION 9
MAJOR COMPONENT DESCRIPTION 11
SPECIFICATIONS 13
GENERAL SAFETY 15
SAFETY RULES 15
SAFETY FEATURES 15
CLOTHING AND PERSONAL PROTECTIVE ITEMS 15
UNAUTHORIZED MODIFICATION 15
LEAVING THE OPERATOR’S SEAT 16
MOUNTING AND DISMOUNTING 16
FIRE PREVENTION FOR FUEL AND OIL 16
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES 17
ASBESTOS DUST HAZARD PREVENTION 17
PREVENTION OF INJURY BY WORK EQUIPMENT 17
FIRE EXTINGUISHER AND FIRST AID KIT 17
PRECAUTIONS WHEN USING ROPS 18
PRECAUTIONS FOR ATTACHMENTS 18
PRECAUTIONS ON STARTING MACHINE 18
PRECAUTIONS DURING OPERATION 19
SAFETY IS THINKING AHEAD 19
SAFETY AT WORKSITE 19
FIRE PREVENTION 19
PREPARING FOR OPERATION 19
VENTILATION FOR ENCLOSED AREAS 19
IN OPERATOR’S CAB – BEFORE STARTING ENGINE 20
KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN 20
OPERATING THE MACHINE 20
WHEN STARTING ENGINE 20
Truck Operation – General 20
CHECK WHEN TRAVELING IN REVERSE 21
TRAVELING 21
TRAVELING ON SLOPES 22
ENSURE GOOD VISIBILITY 22
OPERATE CAREFULLY ON SNOW 22
AVOID DAMAGE TO DUMP BODY 22
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 22
WHEN DUMPING 23
WORKING ON LOOSE GROUND 23
WHEN LOADING 23
PARKING THE MACHINE 23
TOWING 23
WHEN TOWING, FIX WIRE TO HOOK 23
BATTERY 24
BATTERY HAZARD PREVENTION 24
STARTING WITH BOOSTER CABLES 24
PRECAUTIONS FOR MAINTENANCE 25
BEFORE CARRYING OUT MAINTENANCE 25
WARNING TAG 25
PROPER TOOLS 25
STOPPING THE ENGINE BEFORE SERVICE 25
SECURING THE DUMP BODY 25
DURING MAINTENANCE 26
PERSONNEL 26
ATTACHMENTS 26
WORK UNDER THE MACHINE 26
KEEP THE MACHINE CLEAN 26
RULES TO FOLLOW WHEN ADDING FUEL OR OIL 26
RADIATOR WATER LEVEL 27
USE OF LIGHTING 27
PRECAUTIONS WITH BATTERY 27
HANDLING HIGH-PRESSURE HOSES 27
PRECAUTIONS WITH HIGH PRESSURE OIL 27
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE 28
ROTATING FAN AND BELT 28
WASTE MATERIALS 28
TIRES 29
HANDLING TIRES 29
STORING TIRES AFTER REMOVAL 29
ADDITIONAL JOB SITE RULES 30
WHEN REPAIRS ARE NECESSARY 31
OPERATING INSTRUCTIONS 33
PREPARING FOR OPERATION 33
SAFETY IS THINKING AHEAD 33
ENGINE START-UP SAFETY PRACTICES 36
AFTER ENGINE HAS STARTED 37
MACHINE OPERATION SAFETY PRECAUTIONS 38
MACHINE OPERATION ON THE HAUL ROAD 38
DYNAMIC RETARDING OPERATION 39
OPTIONAL – DUAL FUNCTION / SINGLE PEDAL 39
STARTING ON A GRADE WITH A LOADED TRUCK 40
PASSING 40
LOADING 40
DUMPING 40
To Raise dump body: 40
To Lower Body 41
To Lower Body 41
SAFE PARKING PROCEDURES 42
TOWING 42
NORMAL ENGINE SHUTDOWN PROCEDURE 43
DELAYED ENGINE SHUTDOWN PROCEDURE 43
SUDDEN LOSS OF ENGINE POWER 44
WARNINGS AND CAUTIONS 47
STANDARD CHARTS AND TABLES 55
STORAGE AND IDLE MACHINE PREPARATION 61
SHORT TERM IDLE PERIODS 61
PREPARATION FOR STORAGE 62
REMOVAL FROM STORAGE 63
RECONDITIONING AN IDLE VEHICLE 65
ENGINE OPERATION 68
AFTER ENGINE HAS STARTED 69
ENGINE STORAGE-CUMMINS 70
Engine Storage-(Short Term) 70
Prepare the Engine for Short Term Storage 70
Remove the Engine from Short Term Storage 70
Engine Storage- (Long Term) 71
6 Months to 24 Months 71
Prepare the Engine for Long Term Storage 71
Remove the Engine from Long Term Storage 71
ENGINE STORAGE – DETROIT DIESEL 72
Preparing Engine For Storage 72
Temporary Storage (30 Days Or Less) 72
Extended Storage (more Than 30 Days) 72
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE 74
ELECTRIC DRIVE TRUCKS 75
Storage Instructions and Procedures 75
Placing Equipment Into Storage 75
When Storing A Truck That Is Operational 75
When Storing A Truck That Is Not Operational 76
When Storing A Major Component 76
Periodic Inspections 77
Placing Equipment Into Service After Storage 77
When A Truck Is Operational 77
When A Truck Is Not Operational 77
For The First Hour 78
PRESERVATION AND STORAGE ALLISON TRANSMISSION 79
Storage, New Transmission 79
Storage, One Year — Without Oil 79
Storage, One Year With Oil (normally in a vehicle chassis) 79
Restoring Transmission to Service 79
STRUCTURES 81
STRUCTURAL COMPONENTS 83
LADDERS 83
Installation 84
Removal 84
RIGHT HAND DECK 84
Removal 84
Installation 84
CENTER AND LEFT HAND DECK COMPONENTS 85
FUEL TANK 86
Removal 86
Installation 86
DUMP BODY 87
Removal 87
Installation 88
BODY PADS 89
Adjustment 90
BODY GUIDE 90
BODY-UP RETENTION CABLE 90
BODY POSITION INDICATOR 91
ROCK EJECTORS 91
Inspection 91
HOIST LIMIT SWITCH 91
BODY UP SWITCH 91
ENGINE 93
POWER MODULE 95
PREPARATION 95
Removal 95
Installation 99
COOLING SYSTEM 101
COOLING SYSTEM DESCRIPTION 101
RADIATOR 102
Removal 102
Service 104
Installation 104
RADIATOR FILLING PROCEDURE 104
POWER TRAIN 105
ALTERNATOR REMOVAL PROCEDURE 105
ENGINE ALTERNATOR MATING 107
Measuring Procedure 107
Joining Alternator and Engine 109
ENGINE 110
Removal 110
Installation 110
AIR FILTRATION SYSTEM 111
AIR CLEANER 111
Operation 111
General Service Information 111
MAIN FILTER ELEMENT 111
Removal 111
Installation 112
SAFETY FILTER ELEMENT 113
Removal 113
Installation 113
AIR INTAKE TROUBLESHOOTING 113
AIR CLEANER ASSEMBLY CLEANING 113
Main Filter Cleaning 113
Precleaner Section Cleaning 114
FAN CLUTCH 117
REMOVAL & INSTALLATION TOOLING 117
FAN CLUTCH – DISASSEMBLY 120
CLEANING AND INSPECTION 130
ASSEMBLY – FAN CLUTCH 134
TEST PROCEDURE 148
ELECTRICAL SYSTEM (24VDC NON-PROPULSION 149
24VDC ELECTRIC SUPPLY SYSTEM 151
ELECTRICAL SYSTEM DESCRIPTION 151
BATTERY 151
Maintenance and Service 151
Troubleshooting 151
BATTERY CHARGING SYSTEM (Niehoff) 153
General Description 153
TROUBLESHOOTING PROCEDURES (On-Truck) 153
Preliminary Checks 154
Test Setup 154
Test Procedure 154
Regulator Bypass Test 155
ON VEHICLE TROUBLESHOOTING GUIDE – SELF ENERGIZED ALTERNATOR 156
ALTERNATOR ELECTRICAL CONDITION – Low Voltage – High Voltage – No Voltage 156
PRELIMINARY PROCEDURES 156
LOW VOLTAGE OUTPUT 156
HIGH VOLTAGE OUTPUT 156
NO VOLTAGE OUTPUT 156
TOOLS AND EQUIPMENT: 156
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 156
Low Maintenance Types: 156
Maintenance Free types: 157
High-Cycle Maintenance Free Types: 157
DEFINITIONS 157
ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized 158
NO ALTERNATOR OUTPUT 158
STATIC TEST – ENGINE OFF, KEY ON, BATTERY SWITCH ON 158
GO TO ALTERNATOR” 158
GO TO “R” TERMINAL ON ALTERNATOR 158
RE-TEST CHARGING CIRCUIT FOR OPERATION with ENGINE RUNNING 158
GO TO REGULATOR (IF REQUIRED) 159
GO TO REGULATOR CONNECTOR ON ALTERNATOR 159
MAINTENANCE 161
Prelube System Operation Checks 161
Check Valve 161
Timer Solenoid 161
24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE) 160
OPERATION 160
Pressure Switch 161
Check Valve 161
Timer Solenoid 161
Troubleshooting Prelube Starter Circuit 162
24 VDC ELECTRIC START SYSTEM 164
CRANKING MOTORS 164
OPERATION 164
Removal 164
Installation 164
CRANKING MOTOR TROUBLESHOOTING 165
Preliminary Inspection 165
No-Load Test 165
Interpreting Results of Tests 165
Disassembly 166
Cleaning and Inspection 168
Armature Servicing 168
Field Coil Checks 168
Field Coil Removal 168
Solenoid Checks 169
Test 169
Assembly 170
Bearing Replacement: 170
Motor Assembly: 170
Pinion Clearance 171
MAGNETIC SWITCH 171
Installation 171
Coil Test 172
24 VDC ELECTRICAL SYSTEM COMPONENTS 173
PASSENGER SEAT BASE COMPARTMENT 173
COMPONENTS 173
TAIL LIGHT RESISTOR DIODE ASSEMBLIES 173
INCLINOMETER 173
BRAKE WARNING BUZZER (BWB) 173
LUBRICATION SYSTEM TIMER 173
5 MINUTE IDLE TIMER COMPONENTS 173
5 Minute Idle Timer 175
5 Minute Idle Relay 175
5 Minute Idle Contactor 175
5 MINUTE IDLE CIRCUIT TEST 175
DATA STORE SWITCH 175
KOMATSU ENGINE QUANTUM CONNECTOR 175
KOMATSU ENGINE CENSE CONNECTOR 175
STATEX III PROPULSION SYSTEM DIAGNOSTIC CONNECTOR 175
SPARE CONNECTOR LOCATION 175
ALARM INDICATING DEVICE (AID) SYSTEM 176
Diode Matrix (Without Sound) 176
Diode Matrix (With Sound) 176
Hot Switch Inverter 177
Hot Switch Inverter Card (Slot 4) (Not Used) 177
Temperature 177
Oil Level 177
Temperature and Latch 177
Coolant Level/Flasher 177
Lamp Test 177
BATTERY EQUALIZER BOX 178
Troubleshooting 178
BODY-UP SWITCH 179
Adjustment 179
Service 179
HOIST LIMIT SWITCH 179
Adjustment 179
Service 179
24 VOLT RELAY AND DIODE BOARDS 180
RELAY BOARDS 180
Description 180
SERVICE 181
To replace a relay: 181
To replace a circuit breaker: 181
To replace a circuit panel card 182
RELAY BOARD COMPONENTS 182
DIODE BOARD 1 185
Diode Testing 185
CIRCUIT BREAKERS 186
ELECTRICAL PROPULSION COMPONENTS 187
ELECTRICAL PROPULSION COMPONENTS 189
GENERAL SYSTEM DESCRIPTION 189
CONTROL SYSTEM 189
System Operation 190
FL275 Panel 191
CARD REPLACEMENT 192
Removal 192
Installation 192
Card Repair 192
Panel Wiring 192
COMPUTER DESCRIPTION 193
Microprocessor 193
Download Capability 193
SOFTWARE 193
Base Monitor Program 193
Runtime Monitor Program – OBJ Running Code 193
Configuration Software – CFG 194
PTU – Portable Test Unit Code 194
System Regulation 194
Propulsion 195
Retarding 195
2-DIGIT DISPLAY PANEL 196
The Coded Number 196
Events 196
Frames 197
Windows 197
System Categories 197
Limits On Resetting Faults 197
NA Faults 198
Event Sequence 198
Resetting Events 198
Event Descriptions 198
Subcode Descriptions 198
2-DIGIT DISPLAY PANEL CODES 199
2-DIGIT DISPLAY PANEL SUBCODES 206
PORTABLE TEST UNIT (PTU) 209
DESCRIPTION 209
Operational Hints 209
Hard Disk Space Requirements 210
SOFTWARE INSTALLATION ON PTU 210
PTU/Truck Communication Problems 211
THE MAIN MENU 212
“Quit Menu” 212
“PTU Talk To Truck” 212
“View PTU Saved Files” 212
“List Stat Data Files” 212
“Truck Setup (CFG)” 212
“Select Truck Setup” 212
“Update CFG Version” 212
“Change PTU Password” 212
CONFIGURATION (CFG) FILE CONVERSION 214
Conversion Procedure 214
Convert old CFG files for new software: 215
STATEX CONFIGURATION FILES 218
“0) Source Directory: ” 218
“1) Select A Truck Configuration ” 219
“2) View Truck Configuration: Data Curves ” 220
“3) Change/View Serial and Model Numbers ” 221
“4) View Options ” 221
“5) Change/View Truck Specifics ” 223
“6) Change/View Overspeeds ” 225
“7) Save a Truck Configuration, filename: ” 226
“8) Save Directory: ” 227
“CHANGE PTU PASSWORD” 228
PROGRAMMING THE TRUCK 229
Connect PTU to the Truck 229
Select Configuration File 229
Activate The PTU Mode 229
Check Object Code Version 230
Download Configuration Files 231
Date And Time 232
Event Data 233
Statistical Data 235
“View Counters” 235
“View Profiles” 235
“Upload Statistical Data To A File” 235
Statistical Data Codes – Counters 236
STATISTICAL DATA CODES – COUNTERS 237
STATISTICAL DATA CODES – PROFILES 242
TRUCK SPECIFIC INFORMATION 246
Temporary Truck Settings 247
MISCELLANEOUS FEATURES 248
Saving Data 248
PTU Abbreviations 249
Other Menu Selections 249
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 250
ALTERNATOR 250
ELECTRIC WHEEL MOTORS 250
RETARDING GRIDS 250
ELECTRONIC ACCELERATOR AND RETARD PEDALS 250
Removal 250
Installation 250
Disassembly 251
Reassembly 251
COOLING BLOWER WARNING SYSTEM 252
Operation 252
Test 252
Removal 252
Installation 252
ELECTRICAL CONTROL CABINET 253
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 258
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 259
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 261
GENERAL INFORMATION 263
COMMUNICATIONS PORT CHECK 264
PTU Hookup 264
1 0 SEQUENCE TESTS – (Engine not running) 266
1 1 Throttle System Check and Adjustment 267
1 1 1 Electronic Throttle System (Williams electronic foot pedal, Dresser ACC/RET Interface Circuit and Pedal Detector Card) 267
1 1 2 Electronic Throttle System (Fuel Saver System) 268
1 2 Retard System Check and Adjustment 270
1 2 1 Williams Electronic Retard Pedal and Dresser ACC/RET or RET Interface Box 270
1 2 2 Electronic Retard Pedal; Fuel Saver Equipped Trucks and Current Production 271
1 3 Reverser and Propulsion Contactors Check 273
1 4 Propulsion Lockout Test (DDEC & MTU Engine Trucks Only) 274
1 5 Retard Contactors Operation Check 275
1 6 Ground Fault Sensing Check 275
1 7 Ground Fault in Retard Operation Check 275
1 8 Override Operation Check 276
1 9 Anti-Reversal Function (AR) Check 277
1 10 Overspeed Retard Operation Check 277
1 11 Hoist Interlock Operation Check 278
1 12 Motor Blower Fault Light Operation Check 279
2 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 280
2 1 Setup Manual Digital Input/Output Test on PTU 280
2 2 Digital Input Checks 281
2 3 Digital Output Checks 283
3 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 286
3 1 Setup Analog Input Monitor Screen on PTU 286
3 2 Analog Input Checks 287
3 3 Frequency Input Checks 294
4 0 SPEED EVENT CHECKS 296
4 1 Single Speed Overspeed Truck – Overspeed Settings Check 297
4 2 Two Speed Overspeed Truck (Empty Truck) – Overspeed Settings Check 297
4 3 Two Speed Overspeed Truck (Loaded Truck) – Overspeed Settings Check 297
4 4 Other Speed Events Checks 297
5 0 RETARD SPEED CONTROL SYSTEM CHECK 299
5 1 Overspeed Pickup and Dropout Check 299
5 2 Retard Pot Maximum Setting Check 300
5 3 Retard Pot Minimum Setting Check 300
5 4 Accelerator Pedal Override of Retard Speed Control 300
6 0 LOAD TEST USING TRUCK RETARD GRIDS 301
6 1 Load Test 302
7 0 MOTOR FIELD CURRENT CHECK IN RETARDING 303
7 1 Retard Check 303
8 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 304
8 1 Brake System Interlocks Check 304
8 2 Blower Loss Pressure Switch Adjustment 305
8 3 SYNC Transformer Checkout 305
8 4 Power Contactor Position Sensor Adjustment 305
8 5 Battery Boost Adjustment 306
8 6 Isolation amplifier & voltage module test 306
8 6 1 Voltage Measuring Module Test (VMM1 and VMM2) 306
8 6 2 ISOA3, ISOA4, ISOA5, ISOA6, ISOA-7, and ISOA-8 Test 307
8 7 Motor Rotation Test 307
8 8 Ground Fault Checks 308
9 0 MISCELLANEOUS CHARTS 309
9 1 Wheel Motor Gear Ratios 309
9 2 Maximum Allowable Truck Speeds 310
9 3 Engine Options 311
DRIVE AXLE, SPINDLE AND WHEELS 313
TIRES AND RIMS 315
FRONT TIRES AND RIMS 315
Removal 315
Installation 316
REAR TIRES AND RIMS 317
Removal 317
Installation 318
RIM 319
RIM AND TIRE PREPARATION 319
Tire Removal 319
LUBRICANTS 320
TIRE INSTALLATION 320
FRONT WHEEL HUB AND SPINDLE 323
WHEEL HUB AND SPINDLE ASSEMBLY 323
Removal 323
Spindle Pusher Tool Usage 324
Installation 325
Disassembly 327
Cleaning and Inspection 327
Assembly 328
Wheel Bearing Adjustment (Tire Removed) 330
Wheel Bearing Adjustment (Tire mounted) 330
STEERING CYLINDERS AND TIE ROD 332
Spherical Bearing Wear Limits 332
Removal 333
Installation 333
Bearing Replacement 333
TOE-IN ADJUSTMENT 335
REAR AXLE HOUSING ATTACHMENT 337
PIVOT PIN 337
Removal 337
Installation 337
PIVOT EYE BEARING 338
Disassembly 338
Assembly 338
PIVOT EYE REPAIR 339
Removal 339
Disassembly 339
Assembly 339
Installation 339
ANTI-SWAY BAR 340
Removal 340
Installation 340
Disassembly 340
Cleaning and Inspection 340
Assembly 340
REAR AXLE HOUSING 341
REAR AXLE HOUSING 341
Removal 341
Installation 341
WHEEL MOTOR 341
Removal 341
Cleaning and Inspection 342
Installation 342
Maximum Capscrew Usage 342
SUSPENSIONS 343
FRONT SUSPENSION 345
Removal 345
Installation 346
MAXIMUM CAPSCREW USAGE 347
“TURN-OF-THE-NUT” Tightening Procedure 348
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 349
Bearing Structure Removal 349
Bearing Structure Installation 349
MAJOR SUSPENSION REBUILD 350
Disassembly 350
Assembly 351
PRESSURE TEST 352
REAR SUSPENSIONS 353
Removal 353
Installation 355
Disassembly 357
Cleaning and Inspection 357
Assembly 357
PRESSURE TEST 358
OILING AND CHARGING PROCEDURE 359
GENERAL 359
EQUIPMENT LIST 359
HYDRAIR® CHARGING KIT 359
Installation of Charging Kit 359
Removal of Charging Kit 360
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 360
FRONT SUSPENSION 361
Front Suspension Oiling 361
Front Suspension Nitrogen Charging 362
REAR SUSPENSION 363
Rear Suspension Oiling 363
Rear Suspension Nitrogen Charging 364
OIL AND NITROGEN SPECIFICATIONS CHART 366
BRAKE CIRCUIT 367
BRAKE CIRCUIT 369
SERVICE BRAKE CIRCUIT OPERATION 369
SECONDARY BRAKING AND AUTOMATIC APPLY 371
PARKING BRAKE CIRCUIT 371
Normal Operation (key switch on, engine running) 371
BRAKE LOCK CIRCUIT 372
WARNING CIRCUIT 372
BRAKE CIRCUIT COMPONENT SERVICE 375
BRAKE VALVE 375
Rebuild Criteria 375
Removal 375
DISASSEMBLY 378
Cleaning and Inspection 380
ASSEMBLY 380
Actuator Base Threaded Inserts 380
Boot and Cap 380
Valve Body Seal Installation 381
Regulator Sleeve O-Ring Installation 381
Actuator Plunger O-ring Installation 381
Assembly of Valve 382
DIFFERENTIAL PRESSURE SWITCH 383
Disassembly 383
Cleaning and Inspection 383
Assembly 383
VALVE BENCH TEST AND ADJUSTMENT 384
Test Set Up Procedure 385
Brake Valve Output Pressure Adjustment 385
Differential Pressure Switch Test 385
Final Test and Adjustment 386
Installation Of Brake Pedal Actuator Assembly to Brake Valve 387
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal) 388
Installation of Retard Pedal To Brake Pedal 388
HYDRAULIC BRAKE ACCUMULATORS 389
Brake Accumulator Bleed Down Procedure 389
Removal 389
Installation 389
Disassembly 389
Cleaning and Inspection 390
Assembly 391
Charging Procedure 392
BRAKE MANIFOLD 393
Removal 393
Removal 393
Installation 394
Disassembly 394
Cleaning and Inspection 394
Assembly 394
BRAKE CIRCUIT CHECK-OUT PROCEDURE 395
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 401
EQUIPMENT REQUIRED 397
INITIAL SYSTEM SET-UP 398
PARKING BRAKE 398
BRAKE SYSTEM CHECK-OUT 398
Failure Modes Check-Out 399
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 405
ROCKWELL WHEEL SPEED FRONT DISC BRAKES 407
BRAKE CALIPER 407
Caliper Removal 407
Installation 408
Disassembly 409
Assembly 409
Cleaning and Inspection 410
BRAKE LINING 411
Replacement 411
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 412
SAFETY PRECAUTIONS 412
Front Brake Conditioning 412
BRAKE BLEEDING PROCEDURES 413
ROCKWELL ARMATURE SPEED REAR DISC BRAKES 415
REAR BRAKES 415
CALIPER, DISC, AND PARKING BRAKE 415
Caliper, Disc, and Parking Brake Removal 415
Caliper, Disc, And Parking Brake Installation 416
CALIPER, DISC, & PARKING BRAKE REMOVAL [For trucks equipped with one-piece adapter (16, Figure 6-3A)] 418
Caliper, Disc, And Parking Brake Installation 419
CALIPER PISTON 420
Piston Assembly Removal 420
Inspection 420
Piston Assembly Installation 420
FUNCTIONAL TEST OF PISTON ASSEMBLY 421
Return Spring Force 421
Built-In Clearance 421
Grip Force 422
Grip Force Measurement 423
Spring Force Measurement 424
Disassembly of Piston Assembly 425
Assembly of Piston Assembly 426
BENCH TEST 426
BRAKE LINING 427
Replacement 427
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 430
General 430
Safety Precautions 430
Rear Brake Conditioning 431
BRAKE BLEEDING PROCEDURE 432
ROCKWELL DISC PARKING BRAKE 433
PARK BRAKE CALIPER 433
Removal 433
Installation 434
Parking Brake Adjustment 434
Park Brake Caliper Disassembly 436
Cleaning and Inspection 436
Park Brake Caliper Assembly 437
PARK BRAKE LINING REPLACEMENT 438
PARK BRAKE BURNISH PROCEDURE 438
Lining Conditioning 438
BRAKE BLEEDING PROCEDURE 438
HYDRAULIC SYSTEM 439
HYDRAULIC SYSTEM 441
HYDRAULIC SYSTEM OPERATION 441
COMPONENT DESCRIPTION 442
HYDRAULIC SYSTEM COMPONENT REPAIR 445
HOIST PUMP 445
Removal 445
Installation 446
Disassembly 447
INSPECTION OF PARTS 450
Assembly 451
HYDRAULIC TANK 456
Filling Instructions 456
Removal 456
Installation 457
HYDRAULIC TANK STRAINERS 457
Removal 457
Inspect and Clean 457
Installation 457
HYDRAULIC TANK BREATHERS 458
HOIST CIRCUIT FILTERS 458
FILTER ELEMENT REPLACEMENT 459
Removal 459
INDICATOR SWITCH 459
STEERING CIRCUIT 461
STEERING CIRCUIT OPERATION 461
COMPONENT DESCRIPTION 462
STEERING CONTROL UNIT 462
FLOW AMPLIFIER 462
No Steer 464
Steering Left 466
Steering Right 468
No Steer, External Shock Load 470
BLEED DOWN MANIFOLD 472
ACCUMULATORS 473
Low Precharge Warning Switch 473
HIGH PRESSURE FILTER 473
STEERING/BRAKE PUMP 473
Operation 474
PRINCIPLE OF OPERATION 476
Full Pump Volume: 476
Half Pump Volume: 476
STEERING CIRCUIT COMPONENT REPAIR 479
BLEED DOWN MANIFOLD 479
Removal 479
Installation 479
ACCUMULATOR 480
Removal 480
Installation 481
Disassembly 481
Cleaning and Inspection 481
Assembly 482
LEAK TESTING 483
STEERING ACCUMULATOR CHARGING PROCEDURE 484
Temperature During Precharge 487
ACCUMULATOR STORAGE PROCEDURES 488
INstructions For Storing Bladder Accumulators 488
Instructions For Installing A Bladder Accumulator That Was In A Parts Warehouse Or In Storage 488
Bladder Storage Procedures 489
FLOW AMPLIFIER 490
Removal 490
Installation 490
Disassembly 490
Reassembly 493
STEERING CONTROL UNIT 494
Removal 494
Spline Inspection 494
Installation 494
Disassembly 495
Cleaning and Inspection 496
Assembly 496
STEERING CYLINDER 500
Disassembly 500
Inspection and Cleaning 500
Assembly 500
STEERING CIRCUIT FILTER 501
FILTER ELEMENT REPLACEMENT 501
Removal 502
Installation 502
INDICATOR SWITCH 502
STEERING AND BRAKE PUMP 503
Removal 503
Installation 503
Disassembly 505
Control Piston Group 505
Valve Plate Group 505
Rotating Group 506
Swashblock Group 506
Driveshaft Group 506
INSPECTION 506
Control Piston Group 506
Valve Plate Group 506
Rotating Group 506
Swashblock Group 510
Driveshaft Group 510
Compensator Block and Unloader Module 510
Stroke Adjuster Assembly 510
ASSEMBLY 510
Swashblock Group 510
Control Piston Group 512
Valve Plate Group 512
HOIST CIRCUIT 515
HOIST CIRCUIT OPERATION 515
COMPONENT DESCRIPTION 516
Hydraulic Tank 516
Hoist Pump 516
High Pressure Filters 516
HOIST VALVE 517
HOIST PILOT VALVE 518
HOIST-UP LIMIT SOLENOID 518
PILOT OPERATED CHECK VALVE 518
COUNTERBALANCE VALVE MANIFOLD 518
FLOAT POSITION OF PILOT VALVE AND BODY ON FRAME (Figure 7-6) 520
HOIST SYSTEM OPERATION MODES 519
POWER UP OPERATION (Figure 7-7) 522
FLOAT POSITION OF PILOT VALVE AND BODY ON FRAME (Figure 7-6) 520
HOLD OPERATION (Figure 7-8) 524
POWER DOWN OPERATION (Figure 7-9) 526
FLOAT OPERATION (Figure 7-10) 528
HOIST CIRCUIT COMPONENT REPAIR 531
HOIST VALVE 531
Removal 531
Installation 531
O-Ring Replacement 532
INLET SECTION 532
Disassembly 532
Cleaning and Inspection 533
Assembly 534
SPOOL SECTION 534
Disassembly 534
Cleaning and Inspection 536
Assembly 536
HOIST PILOT VALVE 537
Removal 537
Installation 537
Disassembly 537
Cleaning and Inspection 539
Assembly 539
BODY UP LIMIT SOLENOID 540
PILOT OPERATED CHECK VALVE 540
HOIST CYLINDERS 540
Removal 540
Installation 541
Disassembly 543
Cleaning and Inspection 544
ASSEMBLY OF QUILL AND CYLINDER 545
Quill Installation 545
Installation of Check Balls and Plugs in Quill 546
Assembly of Cylinder 547
COUNTERBALANCE MANIFOLD 548
DISABLED TRUCK DUMPING PROCEDURE 549
HOOKUP 549
DUMPING PROCEDURE 549
HYDRAULIC CHECKOUT PROCEDURE 551
STEERING AND BRAKE PUMP 551
Pressure Check And Adjustment Procedure 551
BLEEDDOWN MANIFOLD 552
SHOCK & SUCTION VALVES 553
Shock & Suction Valve Settings 553
LEAKAGE TESTS 554
Steering Control Unit & Flow Amplifier 554
Bleeddown Manifold 554
ACCUMULATOR BLEED DOWN PROCEDURE 555
LOW STEERING PRESSURE SWITCH 555
TROUBLESHOOTING CHART (Steering Circuit) 556
CHECKING HOIST SYSTEM PRESSURES 562
Hoist System Relief Pressure Adjustment 562
Power Down Relief Pressure Adjustment 563
Hoist Counterbalance Valve Adjustment 564
Preparation: 564
Counterbalance Valve Pressure Check Only: 564
Counterbalance Valve Adjustment 565
TROUBLESHOOTING CHART (Hoist Pump) 566
HYDRAULIC SYSTEM FLUSHING PROCEDURE 568
OIL CLEANLINESS CHECK 569
OPTIONS AND SPECIAL TOOLS 571
FIRE CONTROL SYSTEM (MANUAL) 573
Operation 573
Inspection and Maintenance 573
Recharging Procedures 574
WIGGINS QUICK FILL FUEL SYSTEM 575
FUEL RECEIVER 575
TANK BREATHER VALVE 576
Removal 576
Installation 576
Disassembly 576
Assembly 576
LEFT SIDE FILL 577
BUCKEYE QUICK FUEL SYSTEM 579
FUEL TANK BREATHER VALVE 579
Maintenance 579
Filter Service 579
Disassembly 579
Inspection 579
Assembly 579
FUEL RECEIVER 580
ENGINE COOLANT HEATER 581
Maintenance 581
HEATING ELEMENT 581
Removal 581
Installation 581
THERMOSTAT 582
Removal 582
Installation 582
SPECIAL TOOLS 583
AIR CONDITIONING SYSTEM 589
Environmental Impact 589
OPERATOR CAB AIR CONDITIONING 590
PRINCIPLES OF REFRIGERATION 590
Air Conditioning 590
Refrigeration – The Act Of Cooling 591
The Refrigeration Cycle 591
AIR CONDITIONER SYSTEM COMPONENTS 592
Compressor (Refrigerant Pump) 592
Service Valves 592
Condenser 592
Expansion Block Valve 593
Evaporator 593
ELECTRICAL CIRCUIT 594
Thermostat 594
Compressor Clutch 594
Trinary™ Switch 595
SYSTEM SERVICING 596
SYSTEM OIL 597
Handling and Reusing PAG Oil 597
Oil Quantity 597
Replacing Oil After Servicing the System 597
Setting Up a New Compressor 597
REFRIGERANT 598
Recycled Refrigerant 598
Reclaimed Refrigerant 598
Refrigerant Quantity 598
R-134a Refrigerant Containers 598
SERVICE TOOLS AND EQUIPMENT 599
Recovery/Recycle Station 599
Leak Detector 599
Service Valves 600
Vacuum Pump 600
Manifold Gauge Set 601
Installing Manifold Gauge Set 602
Purging Air From Service Hoses 603
Stabilizing the AC System 604
SYSTEM PERFORMANCE TEST 604
SYSTEM LEAK TESTING 605
Electronic leak detector 605
Tracer dyes 605
Soap and water 605
SYSTEM REPAIR 606
System Cleaning 606
Hoses and Fittings 606
Lines 606
Expansion Valve 606
Receiver-Drier 607
Thermostat 607
Compressor 607
Clutch 607
Servicing the Compressor Clutch 608
Pulley Removal 610
Clutch Coil Check 610
Pulley Installation 610
Clutch Assembly Installation 611
RECOVERING AND RECYCLING THE REFRIGERANT 612
Performing the Recovery Cycle 612
Performing the Recycling Procedure 612
Evacuating and Charging the AC System 612
EVACUATING THE SYSTEM 613
CHARGING THE AC SYSTEM 614
TROUBLESHOOTING 615
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 623
Pre-Diagnosis Checks 615
Preparing For Diagnosis 615
Preliminary Steps 615
System Performance Test 615
Diagnosis Of Gauge Readings And System Performance 616
RADIATOR SHUTTERS 625
PAYLOAD METER III ™ 637
OPERATION SECTION 641
Introduction 641
Data Summary 641
Data Gathering 641
COMPONENT DESCRIPTION 642
System Diagram 642
Suspension Pressure Sensors 642
Inclinometer 642
Operator Display 642
Operator Switch 643
Speed Input 643
Body-Up Switch 643
Brake Lock Switch 643
Payload Meter 643
Communications Ports 643
Keyswitch Input 644
Payload Meter Power 644
Load Lights 644
Wiring and Termination 645
TCI Outputs 645
OPERATOR’S DISPLAY AND SWITCH 646
Reading the Speedometer 646
Reading the Load Display 646
Using the Operator ID 646
Using the Load and Ton Counter 646
Total Ton Counter 646
Total Load Counter 647
Clearing the Counters 647
Viewing Live Sensor Data 647
Other Display Messages 647
PAYLOAD OPERATION & CALCULATION 648
Description of Haul Cycle States 648
Haul Cycle Description 648
Load Calculation 649
Carry Back 649
Measurement Accuracy 649
SOURCES FOR PAYLOAD ERROR 649
Payload Error 649
Loading Conditions 650
Pressure Sensors 650
Swingloads 650
Speed and Distance 650
HAUL CYCLE DATA 650
Haul Cycle Data 651
Haul Cycle Warning Flags 652
M: Haul Cycle Too Long 653
N: Sensor Input Error 653
Alarm Records 653
Frame Torque Data 653
Sprung Weight Data 654
Maximum Speed Data 654
PC SOFTWARE OVERVIEW 654
PC Overview 654
System Configuration 654
Installing the PLMIII Software 654
DOWNLOADING DATA 655
PLM III SYSTEM CONFIGURATION 656
Starting Communications 656
Displayed Payload Units 656
Time Units 656
Connection Menu 656
Connecting to the Payload Meter 657
Configure the Payload Meter 657
Setting the Date and Time 657
Setting the Truck Type 658
Setting the Gauge Display Units 658
Setting the Frame Serial Number 658
Setting the Truck Number 658
Setting the Komatsu Distributor 658
Setting the Komatsu Customer 658
Clean Truck Tare 659
Inclinometer Calibration 659
DATA ANALYSIS 660
Creating a Query 660
Sorting on Truck Unit Number 660
Sorting on Truck Type 660
Sorting on Date Range 661
Sorting on Time Range 661
Payload Detail Screen 662
Creating Reports 662
Summary – one page report 663
Detailed – multi-page report 663
Creating Graphs 664
Exporting Data 664
CSV Export 664
Compressed 665
Importing Data 666
Deleting Haul Cycle Records 666
Viewing Alarms 667
Deleting Alarm Records 667
TROUBLESHOOTING SECTION 668
TROUBLESHOOTING 668
Viewing Active Alarms 668
Real-Time Data Display 668
Testing the Payload Lights 668
Creating Log Files of Inputs 669
Daily Inspections 669
Periodic Maintenance 669
Abnormal Displays at Power-Up 670
No Payload Display When Keyswitch is Turned ON 671
No Display on Speedometer 672
No Display on Operator Display 672
No Communications With PC 673
Load Lights Don’t Light During Loading 674
Load Lights Remain ON 675
Load Lights Remain ON During Dumping 675
Display Doesn’t Clear When The Load Is Dumped 675
Calibration Problems 676
Alarm 1 – Left Front Pressure High 677
Alarm 2 – Left Front Pressure Low 677
Troubleshoot Wiring to Left Front Suspension 677
Alarm 3 – Right Front Pressure High 678
Alarm 4 – Right Front Pressure Low 678
Troubleshoot Wiring to Right Front Suspension 678
Alarm 5 -Left Rear Pressure High 679
Alarm 6 – Left Rear Pressure Low 679
Troubleshoot Wiring to Left Rear Suspension 679
Alarm 7 – Right Rear Pressure High 680
Alarm 8 – Right Rear Pressure Low 680
Troubleshoot Wiring to Right Rear Suspension 680
Alarm 9 – Inclinometer High 681
Alarm 10 – Inclinometer Low 681
Troubleshoot Inclinometer Wiring 681
Alarm 13 – Body Up Input Failure 682
Alarm 15 – Memory Write Failure 683
Alarm 16 – Memory Read Failure 683
Alarm 24 – System Key-On Status 683
Operator Switch Doesn’t Work 684
Alarm 26 – User Switch Fault – SELECT 684
Alarm 27 – User Switch Fault – SET 684
Connector Map 685
Connectors 686
PLMIII CHECK OUT PROCEDURE 687
General Description 687
Tools Required 687
Checkout Procedure 687
PLMIII CHECKOUT PROCEDURE CONFIRMATION 691
Flashburn Programming 691
Confirmation Checklist 693
PAYLOAD METER III COMPONENTS 694
RESERVE ENGINE OIL SYSTEM 695
OPERATORS CAB 701
TRUCK CAB 703
Description 703
Removal 704
Installation 705
CAB DOOR 706
Removal 706
Installation 706
Door Adjustment 706
Door Jamb Bolt Adjustment 706
Door Handle Plunger Adjustment 708
Replace Door Glass 709
Replace Door Window Regulator 713
Replace Door Handle or Latch Assembly 713
Door and Door Hinge Seal Replacement 714
Door Opening Seal Removal 714
Installation 714
GLASS REPLACEMENT 715
ADHESIVE-BONDED WINDOWS 715
Replacement Procedure 715
WINDSHIELD & REAR GLASS 716
Removal 716
Installation 717
CAB COMPONENTS 719
WINDSHIELD WIPERS 719
Wiper Motor 719
Removal 719
Installation 719
Wiper Arm 719
Removal 719
Installation 720
Wiper Linkage 720
Removal 720
Installation 720
WINDSHIELD WASHER 721
Operation 721
Service 721
OPERATOR COMFORT 723
OPERATORS SEAT 723
HEATER/AIR CONDITIONER CONTROLS 724
OPERATION 724
HEATER/AIR CONDITIONER 725
OPERATION 725
HEATER COMPONENTS 725
CIRCUIT BREAKERS 725
RELAYS 725
HEATER CORE 726
FAN MOTOR AND SPEED CONTROL 726
Test 726
ACTUATORS 726
Test 726
FILTER 726
Service 726
AIR CONDITIONER COMPONENTS 726
OPERATOR CONTROLS AND EQUIPMENT 729
STEERING WHEEL AND CONTROLS 730
STEERING COLUMN 731
Removal 731
Steering Column Inspection 731
Installation 731
Horn Button 730
Tilt / Telescope Lever 730
Multi-Function Turn Signal Switch 730
PEDAL CONTROLS 732
Throttle Pedal 732
Service Brake Pedal 732
Optional Dual Function/ Single Pedal 732
Dynamic Retarding Pedal 732
OVERHEAD CONTROLS, GAUGES, ETC 733
Grade/speed Warning Chart 733
Radio Speakers 733
Warning Alarm Buzzer 733
Cab Radio 733
Warning Lights Dimmer Control 733
Status / Warning Indicator Light Panel 733
Windshield Wipers 733
Air Cleaner Vacuum Gauges 734
CENTER CONSOLE CONTROLS 734
F-N-R Selector Switch 734
Hoist Control 735
Ash Tray 735
Lighter 735
Window Switches 735
Engine Shutdown Switch 735
Override Switch 736
Retard Speed Control (RSC) Switch 736
RSC Adjust Dial 736
Operation 736
RSC Control Adjustment 737
Statex III Propulsion System Diagnostic Connector 737
Modular Mining Port Conector 737
Unused Connector 737
Komatsu Engine Quantum Connector 737
Komatsu Engine Cense Connector 737
Data Store Button 737
Passenger Seat 737
Service Engine Light (Blue) 737
Payload Meter (Not Shown) 737
INSTRUMENT PANEL AND INDICATOR LIGHTS 738
CONTROL SYMBOLS 738
INSTRUMENT PANEL 739
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-7) 740
Key Switch 740
Engine Shutdown Switch (with Timer Delay) 740
Operation 740
To Cancel Delay Sequence 740
Fog Lights (Optional) 740
Ladder Light Switch 740
Backup Light Switch 740
Panel Illumination Lights 741
Cab Air Conditioner/heater Vents 741
Engine Cold Weather Starting Aid (Optional) 741
Operation 741
Rotating Beacon Light Switch (Optional) 741
Heated Mirror Switch (Optional) 741
Blank (Not Used In This Application) 741
Wheel Brake Lock Control 741
Operation 741
Parking Brake Control 742
Tachometer 742
Right Turn Signal Indicator 742
High Beam Indicator 742
Left Turn Signal Indicator 742
Speedometer / Payload Meter 742
Voltmeter 742
Engine Oil Pressure Gauge 742
Water Temperature Gauge 743
Fuel Gauge 743
Blank 743
Hourmeter 743
The hourmeter (24, Figure 5- 7) registers the total number of hours the truck engine has been operating 743
Blank 743
Headlight Switch 743
Panel Light Dimmer 743
Payload Meter Switch 743
OVERHEAD STATUS / WARNING INDICATOR LIGHTS 744
INDICATOR LIGHTS 745
LUBRICATION AND SERVICE 751
LUBRICATION AND SERVICE 753
Service Capacities 753
HYDRAULIC TANK SERVICE 753
Adding Oil 753
COOLANT LEVEL CHECK 754
Radiator Filling Procedure 754
Anti-Freeze Specifications 754
RESERVE ENGINE OIL SYSTEM (Optional) 754
Reserve Oil Tank Filling Procedure (Remote fill) 754
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS 756
10 HOUR LUBRICATION AND MAINTENANCE CHECKS 756
LED Light Signals: 756
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 758
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 759
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 760
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (CONTINUED) 761
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 762
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 763
2500 HOUR MAINTENANCE CHECKS 764
5000 HOURS LUBRICATION AND MAINTENANCE CHECKS 765
10,000 HOURS LUBRICATION AND MAINTENANCE CHECKS 765
AUTOMATIC LUBRICATION SYSTEM 767
GENERAL DESCRIPTION 767
SYSTEM COMPONENTS 769
System Operation 770
Normal Operation 770
Pressure Failure Detection Circuits 771
INJECTOR OPERATION 772
STAGE 1 772
STAGE 2 772
STAGE 3 772
STAGE 4 772
GENERAL INSTRUCTIONS 773
LUBRICANT REQUIRED FOR SYSTEM 773
SYSTEM PRIMING 773
FILTER ASSEMBLY 773
LUBRICANT PUMP 774
Pump Housing Oil Level 774
Pump Pressure Control 774
Pressure Control Valve Adjustment 774
INJECTORS (SL-1 Series “H”) 775
Injector Specifications 775
Injector Adjustment 775
SYSTEM CHECKOUT 776
24 VDC TIMER CHECK 776
Lubrication Cycle Timer Adjustment 776
PUMP REBUILD 777
Disassembly 777
Cleaning and Inspection 777
Assembly 779
SYSTEM TROUBLESHOOTING CHART 780
Preventative Maintenance Procedures 783
Daily Lubrication System Inspection 783
250 Hour Inspection 783
1000 Hour Inspection 783
MOTORIZED WHEEL MAINTENANCE SCHEDULE 785
ALPHABETICAL INDEX 789
SYSTEM SCHEMATICS 793
HH353 HYDRAULIC SCHEMATIC 795
HH354 HYDRAULIC BRAKE SCHEMATIC 796
HE481 PAYLOAD METER III SCHEMATIC 797
XS1400 ELECTRIC SCHEMATIC 798
XS1401 INDEX & SYMBOLS 798
XS1402 CIRCUIT NUMBER LOCATOR 799
XS1403 COMPONENT LOCATOR 800
XS1404 COMPONENT LOCATOR 801
XS1405 POWER DISTRIBUTION – 24VDC 802
XS1406 PWR 18 ELEM , 3 STEP RETARDING 803
XS1407 PWR 18 ELEM , 7 STEP RETARDING 804
XS1408 PWR 20 ELEM , 7 STEP RETARDING 805
XS1409 DRIVE SYSTEM CONTROL CIRCUITS 806
XS1410 TWO DIGIT DISPLAY 807
XS1411 G E DIG INPUTS, LUBE CENTER TEST 808
XS1412 REAR TAIL LTS, DIMMER CONTROL 809
XS1413 5 MINUTE IDLE, SPARE WIRES 810
XS1414 WINDOWS, RADIO, GAUGES 811
XS1415 CONTACTOR FEEDBACK 812
XS1416 CONTACTOR COILS 813
XS1417 MACHINE CONTROL CIRCUITS 814
XS1418 ACCELERATOR, RETARD PEDALS 815
XS1419 HYDRAULIC CONTROLS, ALARMS 816
XS1420 HTR/AC, WINDSHIELD WIPER CONTROLS 817
XS1421 LIGHT CONTROL CIRCUITS 818
XS1422 INSTR LIGHTS, DIAGNOSTIC PORTS 819
XS1423 MODULAR MINING DISPATCH 820
XS1424 CUMMINS QSK-60 ENGINE 821
XS1425 CUMMINS QSK-60 ENGINE 822
XS1426 COMBO TURN SIGNAL / WIPER SWITCH 823

S.V 15/12/24