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Komatsu 830E Dump Truck Shop Manual SN A30733 – A30815 – PDF DOWNLOAD
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Komatsu 830E Dump Truck Shop Manual
SERIAL NUMBERS A30733 – A30815
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Description
Komatsu 830E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 830E Dump Truck Shop Manual
Model Specification: KOMATSU 830E DUMP TRUCK
Language: English
File Format: PDF
Total Pages: 823
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU 830E DUMP TRUCK SHOP MANUAL SN A30733 – A30815 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 830E Dump Truck Shop Manual
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
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
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