Komatsu 830E DUMP TRUCK Shop Manual CEBM015101 PDF

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Komatsu 830E DUMP TRUCK Shop Manual CEBM015101 – PDF DOWNLOAD 

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Komatsu 830E DUMP TRUCK Shop Manual CEBM015101 – PDF DOWNLOAD 

Language : English
Pages : 923
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 830E DUMP TRUCK Shop Manual CEBM015101 – PDF DOWNLOAD 

SERIAL NUMBERS A30741 & UP
With Full Time Axle Blower

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.

TABLE OF CONTENTS:

Komatsu 830E DUMP TRUCK Shop Manual CEBM015101 – PDF DOWNLOAD 

SERIAL NUMBERS A30741 & UP
With Full Time Axle Blower

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 45
STANDARD CHARTS AND TABLES 53
STORAGE AND IDLE MACHINE PREPARATION 59
SHORT TERM IDLE PERIODS 59
PREPARATION FOR STORAGE 60
REMOVAL FROM STORAGE 61
RECONDITIONING AN IDLE VEHICLE 63
ENGINE OPERATION 66
AFTER ENGINE HAS STARTED 67
ENGINE STORAGE-CUMMINS 68
Engine Storage-(Short Term) 68
Prepare the Engine for Short Term Storage 68
Remove the Engine from Short Term Storage 68
Engine Storage- (Long Term) 69
6 Months to 24 Months 69
Prepare the Engine for Long Term Storage 69
Remove the Engine from Long Term Storage 69
ENGINE STORAGE – DETROIT DIESEL 70
Preparing Engine For Storage 70
Temporary Storage (30 Days Or Less) 70
Extended Storage (more Than 30 Days) 70
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE 72
ELECTRIC DRIVE TRUCKS 73
Storage Instructions and Procedures 73
Placing Equipment Into Storage 73
When Storing A Truck That Is Operational 73
When Storing A Truck That Is Not Operational 74
When Storing A Major Component 74
Periodic Inspections 75
Placing Equipment Into Service After Storage 75
When A Truck Is Operational 75
When A Truck Is Not Operational 75
For The First Hour 76
PRESERVATION AND STORAGE ALLISON TRANSMISSION 0
Storage, New Transmission 0
Storage, One Year — Without Oil 0
Storage, One Year With Oil (normally in a vehicle chassis) 0
Restoring Transmission to Service 0
STRUCTURES 77
STRUCTURAL COMPONENTS 79
LADDERS 79
Installation 80
Removal 80
RIGHT HAND DECK 80
Removal 80
Installation 80
CENTER AND LEFT HAND DECK COMPONENTS 81
FUEL TANK 82
Removal 82
Installation 82
DUMP BODY 83
Removal 83
Installation 84
BODY PADS 85
Adjustment 86
BODY GUIDE 86
BODY-UP RETENTION CABLE 86
BODY POSITION INDICATOR 87
ROCK EJECTORS 87
Inspection 87
HOIST LIMIT SWITCH 87
BODY UP SWITCH 87
ENGINE 89
POWER MODULE 91
PREPARATION 91
Removal 91
Installation 95
COOLING SYSTEM 97
COOLING SYSTEM DESCRIPTION 97
RADIATOR 98
Removal 98
Service 100
Installation 100
RADIATOR FILLING PROCEDURE 100
POWER TRAIN 101
ALTERNATOR REMOVAL PROCEDURE 101
ENGINE ALTERNATOR MATING 103
Measuring Procedure 103
Joining Alternator and Engine 105
ENGINE 106
Removal 106
Installation 106
AIR FILTRATION SYSTEM 107
AIR CLEANER 107
Operation 107
General Service Information 107
MAIN FILTER ELEMENT 107
Removal 107
Installation 108
SAFETY FILTER ELEMENT 109
Removal 109
Installation 109
AIR INTAKE TROUBLESHOOTING 109
AIR CLEANER ASSEMBLY CLEANING 109
Main Filter Cleaning 109
Precleaner Section Cleaning 110
FAN CLUTCH 113
REMOVAL & INSTALLATION TOOLING 113
FAN CLUTCH – DISASSEMBLY 116
CLEANING AND INSPECTION 126
ASSEMBLY – FAN CLUTCH 130
TEST PROCEDURE 144
ELECTRICAL SYSTEM (24VDC NON-PROPULSION 145
24VDC ELECTRIC SUPPLY SYSTEM 147
ELECTRICAL SYSTEM DESCRIPTION 147
BATTERY 147
Maintenance and Service 147
Troubleshooting 147
BATTERY CHARGING SYSTEM (Niehoff) 149
General Description 149
TROUBLESHOOTING PROCEDURES (On-Truck) 149
Preliminary Checks 150
Test Setup 150
Test Procedure 150
Regulator Bypass Test 151
ON VEHICLE TROUBLESHOOTING GUIDE – SELF ENERGIZED ALTERNATOR 152
ALTERNATOR ELECTRICAL CONDITION – Low Voltage – High Voltage – No Voltage 152
PRELIMINARY PROCEDURES 152
LOW VOLTAGE OUTPUT 152
HIGH VOLTAGE OUTPUT 152
NO VOLTAGE OUTPUT 152
TOOLS AND EQUIPMENT: 152
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 152
Low Maintenance Types: 152
Maintenance Free types: 153
High-Cycle Maintenance Free Types: 153
DEFINITIONS 153
ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized 154
NO ALTERNATOR OUTPUT 154
STATIC TEST – ENGINE OFF, KEY ON, BATTERY SWITCH ON 154
GO TO ALTERNATOR” 154
GO TO “R” TERMINAL ON ALTERNATOR 154
RE-TEST CHARGING CIRCUIT FOR OPERATION with ENGINE RUNNING 154
GO TO REGULATOR (IF REQUIRED) 155
GO TO REGULATOR CONNECTOR ON ALTERNATOR 155
MAINTENANCE 157
Prelube System Operation Checks 157
Check Valve 157
Timer Solenoid 157
24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE) 156
OPERATION 156
Pressure Switch 157
Check Valve 157
Timer Solenoid 157
Troubleshooting Prelube Starter Circuit 158
24 VDC ELECTRIC START SYSTEM 160
CRANKING MOTORS 160
OPERATION 160
Removal 160
Installation 160
CRANKING MOTOR TROUBLESHOOTING 161
Preliminary Inspection 161
No-Load Test 161
Interpreting Results of Tests 161
Disassembly 162
Cleaning and Inspection 164
Armature Servicing 164
Field Coil Checks 164
Field Coil Removal 164
Solenoid Checks 165
Test 165
Assembly 166
Bearing Replacement: 166
Motor Assembly: 166
Pinion Clearance 167
MAGNETIC SWITCH 167
Installation 167
Coil Test 168
24 VDC ELECTRICAL SYSTEM COMPONENTS 169
PASSENGER SEAT BASE COMPARTMENT 169
COMPONENTS 169
TAIL LIGHT RESISTOR DIODE ASSEMBLIES 169
INCLINOMETER 169
BRAKE WARNING BUZZER (BWB) 169
LUBRICATION SYSTEM TIMER 169
5 MINUTE IDLE TIMER COMPONENTS 169
5 Minute Idle Timer 171
5 Minute Idle Relay 171
5 Minute Idle Contactor 171
5 MINUTE IDLE CIRCUIT TEST 171
DATA STORE SWITCH 171
KOMATSU ENGINE QUANTUM CONNECTOR 171
KOMATSU ENGINE CENSE CONNECTOR 171
STATEX III PROPULSION SYSTEM DIAGNOSTIC CONNECTOR 171
SPARE CONNECTOR LOCATION 171
ALARM INDICATING DEVICE (AID) SYSTEM 172
Diode Matrix (Without Sound) 172
Diode Matrix (With Sound) 172
Hot Switch Inverter 173
Hot Switch Inverter Card (Slot 4) (Not Used) 173
Temperature 173
Oil Level 173
Temperature and Latch 173
Coolant Level/Flasher 173
Lamp Test 173
BATTERY EQUALIZER BOX 174
Troubleshooting 174
BODY-UP SWITCH 175
Adjustment 175
Service 175
HOIST LIMIT SWITCH 175
Adjustment 175
Service 175
24 VOLT RELAY AND DIODE BOARDS 176
RELAY BOARDS 176
Description 176
SERVICE 177
To replace a relay: 177
To replace a circuit breaker: 177
To replace a circuit panel card 178
RELAY BOARD COMPONENTS 178
DIODE BOARD 1 181
Diode Testing 181
CIRCUIT BREAKERS 182
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 183
VHMS BASIC FEATURES 183
Gather Data 183
Convert and Record Data 184
Communicate Data to Off-Board Systems 184
USING THE VHMS SYSTEM 185
Turning the VHMS System ON 185
Normal VHMS Operation 186
Turning the VHMS System OFF 186
Downloading from the VHMS controller 186
VHMS DATA ITEMS 187
Fault Codes 187
Machine History 187
VHMS History 187
Snapshots 187
Manual Snapshots 189
Trends 189
Histogram (Load Map) Data 191
Haul Cycle Data 191
Alarm and Snapshot Triggers 193
Satellite Features 195
VHMS DIAGNOSTIC FEATURES 195
Fault History 195
VHMS LED Digits 195
VHMS COMPONENTS 196
VHMS Controller 196
Removal 196
Installation 197
OrbComm Controller 197
Removal 197
Installation 198
Interface Module 198
Removal 199
Installation 199
Temperature Sensors 200
Pressure Sensors 201
VHMS SOFTWARE 203
NECESSARY SOFTWARE 203
NECESSARY TOOLS 203
VHMS TOOL BOX INSTALLATION 204
VHMS SETTING TOOL INSTALLATION 204
VHMS INITIALIZATION PROCEDURE 204
Preliminary Checks 204
Initialization Steps 205
Select Operation 205
VHMS Setting Function 205
Machine Information Setting(1) 205
Machine Information Setting(2) 205
Date & Time Setting 206
GCC Setting 206
Setting Summary 206
VHMS SNAPSHOT PROCEDURE 207
VHMS DOWNLOAD 207
VHMS FTP UPLOAD 208
LOCATION OF DOWNLOAD FILES 209
INSTALLING FLASHBURN PROGRAM 210
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 210
INSTALLING VHMS WATCHER PROGRAM 211
INSTALLING VHMS WATCHER DATA FILES 211
WHEN REPLACING A VHMS CONTROLLER 211
To Set: Date & Time; Satellite; Payload Meter 214
Review Setting Information 215
VHMS CHECKOUT & TROUBLESHOOTING 217
VHMS CHECKOUT PROCEDURE 217
General 217
Structure and Purpose 218
Necessary Equipment: 218
VHMS SYSTEM CHECKOUT 218
Preliminary 218
Checking Inputs To The Interface Module 219
Checking Outputs From The Interface Module 222
VHMS CONTROLLER CHECKOUT 222
TROUBLESHOOTING 223
Communications Networks 223
Coaxial Cable 223
VHMS COMPONENTS 224
VHMS Controller 224
OrbComm Controller 225
Interface Module 225
FAULT CODES 226
Fault History 226
VHMS LED Display Fault Codes 227
Chassis Fault Codes 228
Engine Fault Codes 231
FAULT TREE ANALYSIS 237
Unable to connect to VHMS from laptop PC 237
Flashing Error Code N4-23 (PLM III Communications Fault) 238
Flashing Error Code N4-22 (Engine Communications Fault) 239
No Data Received By WebCARE 240
Coaxial Cable Troubleshooting 241
VHMS FORMS 243
VHMS INITIALIZATION CHECK LIST 243
VHMS DATA DOWNLOAD 244
VHMS INITIALIZATION FORM 244
VHMS INITIALIZATION CHECK LIST 245
VHMS INITIALIZATION FORM 247
ELECTRICAL PROPULSION COMPONENTS 249
ELECTRICAL PROPULSION COMPONENTS 251
GENERAL SYSTEM DESCRIPTION 251
CONTROL SYSTEM 251
System Operation 252
FL275 Panel 253
CARD REPLACEMENT 254
Removal 254
Installation 254
Card Repair 254
Panel Wiring 254
COMPUTER DESCRIPTION 255
Microprocessor 255
Download Capability 255
SOFTWARE 255
Base Monitor Program 255
Runtime Monitor Program – OBJ Running Code 255
Configuration Software – CFG 256
PTU – Portable Test Unit Code 256
System Regulation 256
Propulsion 257
Retarding 257
2-DIGIT DISPLAY PANEL 258
The Coded Number 258
Events 258
Frames 259
Windows 259
System Categories 259
Limits On Resetting Faults 259
NA Faults 260
Event Sequence 260
Resetting Events 260
Event Descriptions 260
Subcode Descriptions 260
2-DIGIT DISPLAY PANEL CODES 261
2-DIGIT DISPLAY PANEL SUBCODES 268
PORTABLE TEST UNIT (PTU) 271
DESCRIPTION 271
Operational Hints 271
Hard Disk Space Requirements 272
SOFTWARE INSTALLATION ON PTU 272
PTU/Truck Communication Problems 273
THE MAIN MENU 274
“Quit Menu” 274
“PTU Talk To Truck” 274
“View PTU Saved Files” 274
“List Stat Data Files” 274
“Truck Setup (CFG)” 274
“Select Truck Setup” 274
“Update CFG Version” 274
“Change PTU Password” 274
CONFIGURATION (CFG) FILE CONVERSION 276
Conversion Procedure 276
Convert old CFG files for new software: 277
STATEX CONFIGURATION FILES 280
“0) Source Directory: ” 280
“1) Select A Truck Configuration ” 281
“2) View Truck Configuration: Data Curves ” 282
“3) Change/View Serial and Model Numbers ” 283
“4) View Options ” 283
“5) Change/View Truck Specifics ” 285
“6) Change/View Overspeeds ” 287
“7) Save a Truck Configuration, filename: ” 288
“8) Save Directory: ” 289
“CHANGE PTU PASSWORD” 290
PROGRAMMING THE TRUCK 291
Connect PTU to the Truck 291
Select Configuration File 291
Activate The PTU Mode 291
Check Object Code Version 292
Download Configuration Files 293
Date And Time 294
Event Data 295
Statistical Data 297
“View Counters” 297
“View Profiles” 297
“Upload Statistical Data To A File” 297
Statistical Data Codes – Counters 298
STATISTICAL DATA CODES – COUNTERS 299
STATISTICAL DATA CODES – PROFILES 304
TRUCK SPECIFIC INFORMATION 308
Temporary Truck Settings 309
MISCELLANEOUS FEATURES 310
Saving Data 310
PTU Abbreviations 311
Other Menu Selections 311
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 312
ALTERNATOR 312
ELECTRIC WHEEL MOTORS 312
RETARDING GRIDS 312
ELECTRONIC ACCELERATOR AND RETARD PEDALS 312
Removal 312
Installation 312
Disassembly 313
Reassembly 313
COOLING BLOWER WARNING SYSTEM 314
Operation 314
Test 314
Removal 314
Installation 314
ELECTRICAL CONTROL CABINET 315
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 320
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 321
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 323
GENERAL INFORMATION 325
COMMUNICATIONS PORT CHECK 326
PTU Hookup 326
1 0 SEQUENCE TESTS – (Engine not running) 328
1 1 Throttle System Check and Adjustment 329
1 1 1 Electronic Throttle System (Williams electronic foot pedal, Dresser ACC/RET Interface Circuit and Pedal Detector Card) 329
1 1 2 Electronic Throttle System (Fuel Saver System) 330
1 2 Retard System Check and Adjustment 332
1 2 1 Williams Electronic Retard Pedal and Dresser ACC/RET or RET Interface Box 332
1 2 2 Electronic Retard Pedal; Fuel Saver Equipped Trucks and Current Production 333
1 3 Reverser and Propulsion Contactors Check 335
1 4 Propulsion Lockout Test (DDEC & MTU Engine Trucks Only) 336
1 5 Retard Contactors Operation Check 337
1 6 Ground Fault Sensing Check 337
1 7 Ground Fault in Retard Operation Check 337
1 8 Override Operation Check 338
1 9 Anti-Reversal Function (AR) Check 339
1 10 Overspeed Retard Operation Check 339
1 11 Hoist Interlock Operation Check 340
1 12 Motor Blower Fault Light Operation Check 341
2 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 342
2 1 Setup Manual Digital Input/Output Test on PTU 342
2 2 Digital Input Checks 343
2 3 Digital Output Checks 345
3 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 348
3 1 Setup Analog Input Monitor Screen on PTU 348
3 2 Analog Input Checks 349
3 3 Frequency Input Checks 356
4 0 SPEED EVENT CHECKS 358
4 1 Single Speed Overspeed Truck – Overspeed Settings Check 359
4 2 Two Speed Overspeed Truck (Empty Truck) – Overspeed Settings Check 359
4 3 Two Speed Overspeed Truck (Loaded Truck) – Overspeed Settings Check 359
4 4 Other Speed Events Checks 359
5 0 RETARD SPEED CONTROL SYSTEM CHECK 361
5 1 Overspeed Pickup and Dropout Check 361
5 2 Retard Pot Maximum Setting Check 362
5 3 Retard Pot Minimum Setting Check 362
5 4 Accelerator Pedal Override of Retard Speed Control 362
6 0 LOAD TEST USING TRUCK RETARD GRIDS 363
6 1 Load Test 364
7 0 MOTOR FIELD CURRENT CHECK IN RETARDING 365
7 1 Retard Check 365
8 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 366
8 1 Brake System Interlocks Check 366
8 2 Blower Loss Pressure Switch Adjustment 367
8 3 SYNC Transformer Checkout 367
8 4 Power Contactor Position Sensor Adjustment 367
8 5 Battery Boost Adjustment 368
8 6 Isolation amplifier & voltage module test 368
8 6 1 Voltage Measuring Module Test (VMM1 and VMM2) 368
8 6 2 ISOA3, ISOA4, ISOA5, ISOA6, ISOA-7, and ISOA-8 Test 369
8 7 Motor Rotation Test 369
8 8 Ground Fault Checks 370
9 0 MISCELLANEOUS CHARTS 371
9 1 Wheel Motor Gear Ratios 371
9 2 Maximum Allowable Truck Speeds 372
9 3 Engine Options 373
DRIVE AXLE, SPINDLE AND WHEELS 375
TIRES AND RIMS 377
FRONT TIRES AND RIMS 377
Removal 377
Installation 378
REAR TIRES AND RIMS 379
Removal 379
Installation 380
RIM 381
RIM AND TIRE PREPARATION 381
Tire Removal 381
LUBRICANTS 382
TIRE INSTALLATION 382
FRONT WHEEL HUB AND SPINDLE 385
WHEEL HUB AND SPINDLE ASSEMBLY 385
Removal 385
Spindle Pusher Tool Usage 386
Installation 387
Disassembly 389
Cleaning and Inspection 389
Assembly 390
Wheel Bearing Adjustment (Tire Removed) 392
Wheel Bearing Adjustment (Tire mounted) 392
STEERING CYLINDERS AND TIE ROD 394
Spherical Bearing Wear Limits 394
Removal 395
Installation 395
Bearing Replacement 395
TOE-IN ADJUSTMENT 397
REAR AXLE HOUSING ATTACHMENT 399
PIVOT PIN 399
Removal 399
Installation 399
PIVOT EYE BEARING 400
Disassembly 400
Assembly 400
PIVOT EYE REPAIR 401
Removal 401
Disassembly 401
Assembly 401
Installation 401
ANTI-SWAY BAR 402
Removal 402
Installation 402
Disassembly 402
Cleaning and Inspection 402
Assembly 402
REAR AXLE HOUSING 403
REAR AXLE HOUSING 403
Removal 403
Installation 403
WHEEL MOTOR 403
Removal 403
Cleaning and Inspection 404
Installation 404
Maximum Capscrew Usage 404
SUSPENSIONS 405
FRONT SUSPENSION 407
Removal 407
Installation 408
MAXIMUM CAPSCREW USAGE 409
“TURN-OF-THE-NUT” Tightening Procedure 410
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 411
Bearing Structure Removal 411
Bearing Structure Installation 411
MAJOR SUSPENSION REBUILD 412
Disassembly 412
Assembly 413
PRESSURE TEST 414
REAR SUSPENSIONS 415
Removal 415
Installation 417
Disassembly 419
Cleaning and Inspection 419
Assembly 419
PRESSURE TEST 420
OILING AND CHARGING PROCEDURE 421
GENERAL 421
EQUIPMENT LIST 421
HYDRAIR® CHARGING KIT 421
Installation of Charging Kit 421
Removal of Charging Kit 422
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 422
FRONT SUSPENSION 423
Front Suspension Oiling 423
Front Suspension Nitrogen Charging 424
REAR SUSPENSION 425
Rear Suspension Oiling 425
Rear Suspension Nitrogen Charging 426
OIL AND NITROGEN SPECIFICATIONS CHART 428
BRAKE CIRCUIT 429
BRAKE CIRCUIT 431
SERVICE BRAKE CIRCUIT OPERATION 431
SECONDARY BRAKING AND AUTOMATIC APPLY 433
PARKING BRAKE CIRCUIT 433
Normal Operation (key switch on, engine running) 433
BRAKE LOCK CIRCUIT 434
WARNING CIRCUIT 434
BRAKE CIRCUIT COMPONENT SERVICE 437
BRAKE VALVE 437
Rebuild Criteria 437
Removal 437
DISASSEMBLY 440
Cleaning and Inspection 442
ASSEMBLY 442
Actuator Base Threaded Inserts 442
Boot and Cap 442
Valve Body Seal Installation 443
Regulator Sleeve O-Ring Installation 443
Actuator Plunger O-ring Installation 443
Assembly of Valve 444
DIFFERENTIAL PRESSURE SWITCH 445
Disassembly 445
Cleaning and Inspection 445
Assembly 445
VALVE BENCH TEST AND ADJUSTMENT 446
Test Set Up Procedure 447
Brake Valve Output Pressure Adjustment 447
Differential Pressure Switch Test 447
Final Test and Adjustment 448
Installation Of Brake Pedal Actuator Assembly to Brake Valve 449
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal) 450
Installation of Retard Pedal To Brake Pedal 450
HYDRAULIC BRAKE ACCUMULATORS 451
Brake Accumulator Bleed Down Procedure 451
Removal 451
Installation 451
Disassembly 451
Cleaning and Inspection 452
Assembly 453
Charging Procedure 454
BRAKE MANIFOLD 455
Removal 455
Removal 455
Installation 456
Disassembly 456
Cleaning and Inspection 456
Assembly 456
BRAKE CIRCUIT CHECK-OUT PROCEDURE 457
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 463
EQUIPMENT REQUIRED 459
INITIAL SYSTEM SET-UP 460
PARKING BRAKE 460
BRAKE SYSTEM CHECK-OUT 460
Failure Modes Check-Out 461
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 467
ROCKWELL WHEEL SPEED FRONT DISC BRAKES 469
BRAKE CALIPER 469
Caliper Removal 469
Installation 470
Disassembly 471
Assembly 471
Cleaning and Inspection 472
BRAKE LINING 473
Replacement 473
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 474
SAFETY PRECAUTIONS 474
Front Brake Conditioning 474
BRAKE BLEEDING PROCEDURES 475
ROCKWELL ARMATURE SPEED REAR DISC BRAKES 477
REAR BRAKES 477
CALIPER, DISC, AND PARKING BRAKE 477
Caliper, Disc, and Parking Brake Removal 477
Caliper, Disc, And Parking Brake Installation 478
CALIPER, DISC, & PARKING BRAKE REMOVAL [For trucks equipped with one-piece adapter (16, Figure 6-3A)] 480
Caliper, Disc, And Parking Brake Installation 481
CALIPER PISTON 482
Piston Assembly Removal 482
Inspection 482
Piston Assembly Installation 482
FUNCTIONAL TEST OF PISTON ASSEMBLY 483
Return Spring Force 483
Built-In Clearance 483
Grip Force 484
Grip Force Measurement 485
Spring Force Measurement 486
Disassembly of Piston Assembly 487
Assembly of Piston Assembly 488
BENCH TEST 488
BRAKE LINING 489
Replacement 489
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 492
General 492
Safety Precautions 492
Rear Brake Conditioning 493
BRAKE BLEEDING PROCEDURE 494
ROCKWELL DISC PARKING BRAKE 495
PARK BRAKE CALIPER 495
Removal 495
Installation 496
Parking Brake Adjustment 496
Park Brake Caliper Disassembly 498
Cleaning and Inspection 498
Park Brake Caliper Assembly 499
PARK BRAKE LINING REPLACEMENT 500
PARK BRAKE BURNISH PROCEDURE 500
Lining Conditioning 500
BRAKE BLEEDING PROCEDURE 500
HYDRAULIC SYSTEM 501
HYDRAULIC SYSTEM 503
HYDRAULIC SYSTEM OPERATION 503
COMPONENT DESCRIPTION 504
HYDRAULIC SYSTEM COMPONENT REPAIR 507
HOIST PUMP 507
Removal 507
Installation 508
Disassembly 509
INSPECTION OF PARTS 511
Assembly 512
AXLE BLOWER PUMP 517
AXLE BLOWER MOTOR 531
Hand Wheel Control 538
HYDRAULIC TANK 540
Filling Instructions 540
Removal 541
Installation 541
HYDRAULIC TANK STRAINERS 541
Removal 541
Inspect and Clean 542
Installation 542
STEERING CIRCUIT 543
STEERING CIRCUIT OPERATION 543
COMPONENT DESCRIPTION 544
Steering Depressurization Solenoid Valve 545
Pilot-to-open Check Valve 545
Pilot-to-open Check Valve Control Solenoid 545
Steering Pump Compensator Vent Solenoid Valve 544
Steering Control Unit 545
HYDRAULIC TANK 546
FLOW AMPLIFIER 546
BLEED DOWN MANIFOLD 556
ACCUMULATORS 557
Low Precharge Warning Switch 557
HIGH PRESSURE FILTER 557
STEERING/BRAKE PUMP 557
STEERING CIRCUIT COMPONENT REPAIR 559
BLEED DOWN MANIFOLD 559
Removal 559
Installation 559
ACCUMULATOR 560
Removal 560
Installation 561
Disassembly 561
Cleaning and Inspection 561
Assembly 562
LEAK TESTING 563
STEERING ACCUMULATOR CHARGING PROCEDURE 564
Temperature During Precharge 567
ACCUMULATOR STORAGE PROCEDURES 568
INstructions For Storing Bladder Accumulators 568
Instructions For Installing A Bladder Accumulator That Was In A Parts Warehouse Or In Storage 568
Bladder Storage Procedures 569
FLOW AMPLIFIER 570
Removal 570
Installation 570
Disassembly 570
Reassembly 573
STEERING CONTROL UNIT 574
Removal 574
Spline Inspection 574
Installation 574
Disassembly 575
Cleaning and Inspection 576
Assembly 576
STEERING CYLINDER 580
Disassembly 580
Inspection and Cleaning 580
Assembly 580
STEERING CIRCUIT FILTER 581
FILTER ELEMENT REPLACEMENT 581
Removal 582
Installation 582
INDICATOR SWITCH 582
STEERING AND BRAKE PUMP 582
Removal 582
Installation 583
Disassembly 588
Inspection 593
Assembly 595
HOIST CIRCUIT 599
HOIST CIRCUIT OPERATION 599
COMPONENT DESCRIPTION 601
Hydraulic Tank 601
Hoist Pump 601
High Pressure Filters 601
HOIST VALVE 602
HOIST PILOT VALVE 603
HOIST-UP LIMIT SOLENOID 603
PILOT OPERATED CHECK VALVE 603
HOIST CONTROLLER 604
COUNTERBALANCE VALVE MANIFOLD 605
HOIST SYSTEM OPERATION MODES 606
FLOAT POSITION OF PILOT VALVE AND BODY ON FRAME (Figure 7-6) 606
POWER UP OPERATION (Figure 7-8) 608
HOLD OPERATION (Figure 7-9) 610
POWER DOWN OPERATION (Figure 7-10) 612
FLOAT OPERATION (Figure 7-11) 614
HOIST CIRCUIT COMPONENT REPAIR 617
HOIST VALVE 617
Removal 617
Installation 617
O-Ring Replacement 618
INLET SECTION 618
Disassembly 618
Cleaning and Inspection 619
Assembly 620
SPOOL SECTION 620
Disassembly 620
Cleaning and Inspection 622
Assembly 622
HOIST PILOT VALVE 623
Removal 623
Installation 623
Disassembly 623
Cleaning and Inspection 625
Assembly 625
BODY UP LIMIT SOLENOID 626
PILOT OPERATED CHECK VALVE 626
HOIST CONTROLLER 626
HOIST CYLINDERS 627
Removal 627
Installation 628
Disassembly 630
Cleaning and Inspection 631
ASSEMBLY OF QUILL AND CYLINDER 632
Quill Installation 632
Installation of Check Balls and Plugs in Quill 633
Assembly of Cylinder 634
COUNTERBALANCE MANIFOLD 635
DISABLED TRUCK DUMPING PROCEDURE 636
HOOKUP 636
DUMPING PROCEDURE 636
HYDRAULIC CHECKOUT PROCEDURE 637
PRELIMINARY SET-UP 637
STEERING AND BRAKE PUMP 638
SHOCK & SUCTION VALVES 640
LEAKAGE TESTS 641
Steering Control Unit & Flow Amplifier 641
Bleeddown Manifold 641
ACCUMULATOR BLEED DOWN PROCEDURE 643
TROUBLESHOOTING CHART (Steering Circuit) 644
AXLE BOX BLOWER CIRCUIT ADJUSTMENTS 650
CHECKING HOIST SYSTEM PRESSURES 652
HOIST CONTROLLER TROUBLESHOOTING PROCEDURE 655
HOIST COUNTERBALANCE VALVE ADJUSTMENT 657
TROUBLESHOOTING CHART (Hoist Pump) 659
HYDRAULIC SYSTEM FLUSHING PROCEDURE 661
OIL CLEANLINESS CHECK 662
OPTIONS AND SPECIAL TOOLS 663
FIRE CONTROL SYSTEM (MANUAL) 665
Operation 665
Inspection and Maintenance 665
Recharging Procedures 666
WIGGINS QUICK FILL FUEL SYSTEM 667
FUEL RECEIVER 667
TANK BREATHER VALVE 668
Removal 668
Installation 668
Disassembly 668
Assembly 668
LEFT SIDE FILL 669
BUCKEYE QUICK FUEL SYSTEM 671
FUEL TANK BREATHER VALVE 671
Maintenance 671
Filter Service 671
Disassembly 671
Inspection 671
Assembly 671
FUEL RECEIVER 672
ENGINE COOLANT HEATER 673
Maintenance 673
HEATING ELEMENT 673
Removal 673
Installation 673
THERMOSTAT 674
Removal 674
Installation 674
SPECIAL TOOLS 675
AIR CONDITIONING SYSTEM 681
Environmental Impact 681
OPERATOR CAB AIR CONDITIONING 682
PRINCIPLES OF REFRIGERATION 682
Air Conditioning 682
Refrigeration – The Act Of Cooling 683
The Refrigeration Cycle 683
AIR CONDITIONER SYSTEM COMPONENTS 684
Compressor (Refrigerant Pump) 684
Service Valves 684
Condenser 684
Expansion Block Valve 685
Evaporator 685
ELECTRICAL CIRCUIT 686
Thermostat 686
Compressor Clutch 686
Trinary™ Switch 687
SYSTEM SERVICING 688
SYSTEM OIL 689
Handling and Reusing PAG Oil 689
Oil Quantity 689
Replacing Oil After Servicing the System 689
Setting Up a New Compressor 689
REFRIGERANT 690
Recycled Refrigerant 690
Reclaimed Refrigerant 690
Refrigerant Quantity 690
R-134a Refrigerant Containers 690
SERVICE TOOLS AND EQUIPMENT 691
Recovery/Recycle Station 691
Leak Detector 691
Service Valves 692
Vacuum Pump 692
Manifold Gauge Set 693
Installing Manifold Gauge Set 694
Purging Air From Service Hoses 695
Stabilizing the AC System 696
SYSTEM PERFORMANCE TEST 696
SYSTEM LEAK TESTING 697
Electronic leak detector 697
Tracer dyes 697
Soap and water 697
SYSTEM REPAIR 698
System Cleaning 698
Hoses and Fittings 698
Lines 698
Expansion Valve 698
Receiver-Drier 699
Thermostat 699
Compressor 699
Clutch 699
Servicing the Compressor Clutch 700
Pulley Removal 702
Clutch Coil Check 702
Pulley Installation 702
Clutch Assembly Installation 703
RECOVERING AND RECYCLING THE REFRIGERANT 704
Performing the Recovery Cycle 704
Performing the Recycling Procedure 704
Evacuating and Charging the AC System 704
EVACUATING THE SYSTEM 705
CHARGING THE AC SYSTEM 706
TROUBLESHOOTING 707
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 715
Pre-Diagnosis Checks 707
Preparing For Diagnosis 707
Preliminary Steps 707
System Performance Test 707
Diagnosis Of Gauge Readings And System Performance 708
RADIATOR SHUTTERS 717
PAYLOAD METER III ™ 729
INDEX 729
OPERATION SECTION 733
Introduction 733
Data Summary 733
Data Gathering 733
COMPONENT DESCRIPTION 734
System Diagram 734
Suspension Pressure Sensors 734
Inclinometer 734
Operator Display 734
Operator Switch 735
Speed Input 735
Body-Up Switch 735
Brake Lock Switch 735
Payload Meter 735
Communications Ports 735
Keyswitch Input 736
Payload Meter Power 736
Load Lights 736
Wiring and Termination 737
TCI Outputs 737
OPERATOR’S DISPLAY AND SWITCH 738
Reading the Speedometer 738
Reading the Load Display 738
Using the Operator ID 738
Using the Load and Ton Counter 738
Total Ton Counter 738
Total Load Counter 739
Clearing the Counters 739
Viewing Live Sensor Data 739
Other Display Messages 739
PAYLOAD OPERATION & CALCULATION 740
Description of Haul Cycle States 740
Haul Cycle Description 740
Load Calculation 741
Carry Back 741
Measurement Accuracy 741
SOURCES FOR PAYLOAD ERROR 741
Payload Error 741
Loading Conditions 742
Pressure Sensors 742
Swingloads 742
Speed and Distance 742
HAUL CYCLE DATA 742
Haul Cycle Data 743
Haul Cycle Warning Flags 744
M: Haul Cycle Too Long 745
N: Sensor Input Error 745
Frame Torque Data 745
Sprung Weight Data 745
Maximum Speed Data 745
Alarm Records 745
Fault Code Data 746
PC SOFTWARE OVERVIEW 747
PC Overview 747
System Configuration 747
Installing the PLMIII Software 747
DOWNLOADING DATA 748
PLM III SYSTEM CONFIGURATION 749
Starting Communications 749
Displayed Payload Units 749
Time Units 749
Connection Menu 749
Connecting to the Payload Meter 750
Configure the Payload Meter 750
Setting the Date and Time 750
Setting the Truck Type 751
Setting the Gauge Display Units 751
Setting the Frame Serial Number 751
Setting the Truck Number 751
Setting the Komatsu Distributor 751
Setting the Komatsu Customer 751
Clean Truck Tare 752
Inclinometer Calibration 752
DATA ANALYSIS 753
Creating a Query 753
Sorting on Truck Unit Number 753
Sorting on Truck Type 753
Sorting on Date Range 754
Sorting on Time Range 754
Payload Detail Screen 755
Creating Reports 755
Summary – one page report 756
Detailed – multi-page report 756
Creating Graphs 757
Exporting Data 757
CSV Export 757
Compressed 758
Importing Data 759
Deleting Haul Cycle Records 759
Viewing Alarms 760
Deleting Alarm Records 760
TROUBLESHOOTING SECTION 761
TROUBLESHOOTING 761
Viewing Active Alarms 761
Real-Time Data Display 761
Testing the Payload Lights 761
Creating Log Files of Inputs 762
Daily Inspections 762
Periodic Maintenance 762
Abnormal Displays at Power-Up 763
No Payload Display When Keyswitch is Turned ON 764
No Display on Speedometer 765
No Display on Operator Display 765
No Communications With PC 766
Load Lights Don’t Light During Loading 767
Load Lights Remain ON 768
Load Lights Remain ON During Dumping 768
Display Doesn’t Clear When The Load Is Dumped 768
Calibration Problems 769
Alarm 1 – Left Front Pressure High 770
Alarm 2 – Left Front Pressure Low 770
Troubleshoot Wiring to Left Front Suspension 770
Alarm 3 – Right Front Pressure High 771
Alarm 4 – Right Front Pressure Low 771
Troubleshoot Wiring to Right Front Suspension 771
Alarm 5 -Left Rear Pressure High 772
Alarm 6 – Left Rear Pressure Low 772
Troubleshoot Wiring to Left Rear Suspension 772
Alarm 7 – Right Rear Pressure High 773
Alarm 8 – Right Rear Pressure Low 773
Troubleshoot Wiring to Right Rear Suspension 773
Alarm 9 – Inclinometer High 774
Alarm 10 – Inclinometer Low 774
Troubleshoot Inclinometer Wiring 774
Alarm 13 – Body Up Input Failure 775
Alarm 16 – Memory Write Failure 776
Alarm 17 – Memory Read Failure 776
Alarm 18 777
Alarm 19 777
Alarm 22 777
Operator Switch Doesn’t Work 778
Alarm 26 – User Switch Fault – SELECT 778
Alarm 27 – User Switch Fault – SET 778
Connector Map 779
Connectors 780
PLMIII CHECK OUT PROCEDURE 781
General Description 781
Tools Required 781
Checkout Procedure 781
PLMIII CHECKOUT PROCEDURE CONFIRMATION 785
Flashburn Programming 785
Confirmation Checklist 787
RESERVE ENGINE OIL SYSTEM 789
OPERATORS CAB 795
TRUCK CAB 797
Description 797
Removal 798
Installation 799
CAB DOOR 800
Removal 800
Installation 800
Door Adjustment 800
Door Jamb Bolt Adjustment 800
Door Handle Plunger Adjustment 802
Replace Door Glass 803
Replace Door Window Regulator 807
Replace Door Handle or Latch Assembly 807
Door and Door Hinge Seal Replacement 808
Door Opening Seal Removal 808
Installation 808
GLASS REPLACEMENT 809
ADHESIVE-BONDED WINDOWS 809
Replacement Procedure 809
WINDSHIELD & REAR GLASS 810
Removal 810
Installation 811
CAB COMPONENTS 813
WINDSHIELD WIPERS 813
Wiper Motor 813
Removal 813
Installation 813
Wiper Arm 813
Removal 813
Installation 814
Wiper Linkage 814
Removal 814
Installation 814
WINDSHIELD WASHER 815
Operation 815
Service 815
OPERATOR COMFORT 817
OPERATORS SEAT 817
HEATER/AIR CONDITIONER CONTROLS 818
OPERATION 818
HEATER/AIR CONDITIONER 819
OPERATION 819
HEATER COMPONENTS 819
CIRCUIT BREAKERS 819
RELAYS 819
HEATER CORE 820
FAN MOTOR AND SPEED CONTROL 820
Test 820
ACTUATORS 820
Test 820
FILTER 820
Service 820
AIR CONDITIONER COMPONENTS 820
OPERATOR CONTROLS AND EQUIPMENT 823
STEERING WHEEL AND CONTROLS 824
STEERING COLUMN 825
Removal 825
Steering Column Inspection 825
Installation 825
Horn Button 824
Tilt / Telescope Lever 824
Multi-Function Turn Signal Switch 824
PEDAL CONTROLS 826
Throttle Pedal 826
Service Brake Pedal 826
Optional Dual Function/ Single Pedal 826
Dynamic Retarding Pedal 826
OVERHEAD CONTROLS, GAUGES, ETC 827
Grade/speed Warning Chart 827
Radio Speakers 827
Warning Alarm Buzzer 827
Cab Radio 827
Warning Lights Dimmer Control 827
Status / Warning Indicator Light Panel 827
Windshield Wipers 827
Air Cleaner Vacuum Gauges 828
CENTER CONSOLE CONTROLS 828
F-N-R Selector Switch 828
Hoist Control 829
Ash Tray 829
Lighter 829
Window Switches 829
Engine Shutdown Switch 829
Override Switch 830
Retard Speed Control (RSC) Switch 830
RSC Adjust Dial 830
Operation 830
RSC Control Adjustment 831
Statex III Propulsion System Diagnostic Connector 831
Modular Mining Port Conector 831
Unused Connector 831
Komatsu Engine Quantum Connector 831
Komatsu Engine Cense Connector 831
Data Store Button 831
Passenger Seat 831
Service Engine Light (Blue) 831
Payload Meter (Not Shown) 831
INSTRUMENT PANEL AND INDICATOR LIGHTS 832
CONTROL SYMBOLS 832
INSTRUMENT PANEL 833
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-7) 834
Key Switch 834
Engine Shutdown Switch (with Timer Delay) 834
Operation 834
To Cancel Delay Sequence 834
Fog Lights (Optional) 834
Ladder Light Switch 834
Backup Light Switch 834
Panel Illumination Lights 835
Cab Air Conditioner/heater Vents 835
Engine Cold Weather Starting Aid (Optional) 835
Operation 835
Rotating Beacon Light Switch (Optional) 835
Heated Mirror Switch (Optional) 835
Blank (Not Used In This Application) 835
Wheel Brake Lock Control 835
Operation 835
Parking Brake Control 836
Tachometer 836
Right Turn Signal Indicator 836
High Beam Indicator 836
Left Turn Signal Indicator 836
Speedometer / Payload Meter 836
Voltmeter 836
Engine Oil Pressure Gauge 836
Water Temperature Gauge 837
Fuel Gauge 837
Blank 837
Hourmeter 837
The hourmeter (24, Figure 5- 7) registers the total number of hours the truck engine has been operating 837
Blank 837
Headlight Switch 837
Panel Light Dimmer 837
Payload Meter Switch 837
OVERHEAD STATUS / WARNING INDICATOR LIGHTS 838
INDICATOR LIGHTS 839
LUBRICATION AND SERVICE 845
LUBRICATION AND SERVICE 847
Service Capacities 847
HYDRAULIC TANK SERVICE 847
Adding Oil 847
COOLANT LEVEL CHECK 848
Radiator Filling Procedure 848
Anti-Freeze Specifications 848
RESERVE ENGINE OIL SYSTEM (Optional) 848
Reserve Oil Tank Filling Procedure (Remote fill) 848
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS 850
10 HOUR LUBRICATION AND MAINTENANCE CHECKS 850
LED Light Signals: 850
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 852
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 853
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 854
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (CONTINUED) 855
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 856
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 857
2500 HOUR MAINTENANCE CHECKS 858
5000 HOURS LUBRICATION AND MAINTENANCE CHECKS 859
10,000 HOURS LUBRICATION AND MAINTENANCE CHECKS 859
AUTOMATIC LUBRICATION SYSTEM 861
GENERAL DESCRIPTION 861
SYSTEM COMPONENTS 863
System Operation 864
Normal Operation 864
Pressure Failure Detection Circuits 865
INJECTOR OPERATION 866
STAGE 1 866
STAGE 2 866
STAGE 3 866
STAGE 4 866
GENERAL INSTRUCTIONS 867
LUBRICANT REQUIRED FOR SYSTEM 867
SYSTEM PRIMING 867
FILTER ASSEMBLY 867
LUBRICANT PUMP 868
Pump Housing Oil Level 868
Pump Pressure Control 868
Pressure Control Valve Adjustment 868
INJECTORS (SL-1 Series “H”) 869
Injector Specifications 869
Injector Adjustment 869
SYSTEM CHECKOUT 870
24 VDC TIMER CHECK 870
Lubrication Cycle Timer Adjustment 870
PUMP REBUILD 871
Disassembly 871
Cleaning and Inspection 871
Assembly 873
SYSTEM TROUBLESHOOTING CHART 874
Preventative Maintenance Procedures 877
Daily Lubrication System Inspection 877
250 Hour Inspection 877
1000 Hour Inspection 877
MOTORIZED WHEEL MAINTENANCE SCHEDULE 879
ALPHABETICAL INDEX 883
SYSTEM SCHEMATICS 887
EG4934 BRAKE SCHEMATIC 889
EK4841 HYDRAULIC SCHEMATIC 890
HE481 PAYLOAD METER III SCHEMATIC 891
XS2100 ELECTRIC SCHEMATIC 892
XS2101 INDEX & SYMBOLS 892
XS2102 CIRCUIT NUMBER LOCATOR 893
XS2103 COMPONENT LOCATOR 894
XS2104 COMPONENT LOCATOR 895
XS2105 POWER DISTRIBUTION – 24VDC 896
XS2106 PWR 18 ELEM , 3 STEP RETARDING 897
XS2107 PWR 18 ELEM , 7 STEP RETARDING 898
XS2108 PWR 20 ELEM , 7 STEP RETARDING 899
XS2109 DRIVE SYSTEM CONTROL CIRCUITS 900
XS2110 TWO DIGIT DISPLAY 901
XS2111 G E DIG INPUTS, LUBE CENTER TEST 902
XS2112 REAR TAIL LTS, DIMMER CONTROL 903
XS2113 5 MINUTE IDLE, SPARE WIRES 904
XS2114 WINDOWS, RADIO, GAUGES 905
XS2115 CONTACTOR FEEDBACK 906
XS2116 CONTACTOR COILS 907
XS2117 MACHINE CONTROL CIRCUITS 908
XS2118 ACCELERATOR, RETARD PEDALS 909
XS2119 HYDRAULIC CONTROLS, ALARMS 910
XS2120 HTR/AC, WINDSHIELD WIPER CONTROLS 911
XS2121 LIGHT CONTROL CIRCUITS 912
XS2122 INSTR LIGHTS, DIAGNOSTIC PORTS 913
XS2123 MODULAR MINING DISPATCH 914
XS2124 CUMMINS QSK-60 ENGINE 915
XS2125 CUMMINS QSK-60 ENGINE 916
XS2126 ELECTRONIC HOIST CONTROLLER 917
EL0114 VHMS SCHEMATIC 918

S.V 14/12/24