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Komatsu 830E Dump Truck Shop Manual SN A30741 & UP – PDF DOWNLOAD
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Komatsu 830E Dump Truck Shop Manual
Book Code: CEBM015101
SERIAL NUMBERS : A30741 & UP
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Description
Komatsu 830E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 830E Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 830E
Serial Number: A30741 & UP
Book Code: CEBM015101
Language: English
Pages: 923
File Format: Portable Document Format (PDF)
KOMATSU 830E DUMP TRUCK SHOP MANUAL SN A30741 & UP – 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......................................................................................................................... 45 STANDARD CHARTS AND TABLES.................................................................................................................... 53 STORAGE AND IDLE MACHINE PREPARATION.......................................................................................................... 59 SHORT TERM IDLE PERIODS................................................................................................................... 59 PREPARATION FOR STORAGE................................................................................................................... 60 REMOVAL FROM STORAGE.................................................................................................................. 61 RECONDITIONING AN IDLE VEHICLE............................................................................................................ 63 ENGINE OPERATION.......................................................................................................................... 66 AFTER ENGINE HAS STARTED.................................................................................................................. 67 ENGINE STORAGE-CUMMINS.................................................................................................................... 68 Engine Storage-(Short Term)............................................................................................................... 68 Prepare the Engine for Short Term Storage................................................................................................. 68 Remove the Engine from Short Term Storage................................................................................................. 68 Engine Storage- (Long Term)............................................................................................................... 69 6 Months to 24 Months................................................................................................................. 69 Prepare the Engine for Long Term Storage.................................................................................................. 69 Remove the Engine from Long Term Storage.................................................................................................. 69 ENGINE STORAGE - DETROIT DIESEL........................................................................................................... 70 Preparing Engine For Storage.............................................................................................................. 70 Temporary Storage (30 Days Or Less)....................................................................................................... 70 Extended Storage (more Than 30 Days)...................................................................................................... 70 PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE........................................................... 72 ELECTRIC DRIVE TRUCKS..................................................................................................................... 73 Storage Instructions and Procedures....................................................................................................... 73 Placing Equipment Into Storage............................................................................................................ 73 When Storing A Truck That Is Operational.................................................................................................. 73 When Storing A Truck That Is Not Operational.............................................................................................. 74 When Storing A Major Component............................................................................................................ 74 Periodic Inspections...................................................................................................................... 75 Placing Equipment Into Service After Storage.............................................................................................. 75 When A Truck Is Operational........................................................................................................... 75 When A Truck Is Not Operational....................................................................................................... 75 For The First Hour.................................................................................................................... 76 PRESERVATION AND STORAGE ALLISON TRANSMISSION............................................................................................. 0 Storage, New Transmission............................................................................................................. 0 Storage, One Year -- Without Oil...................................................................................................... 0 Storage, One Year With Oil (normally in a vehicle chassis)............................................................................ 0 Restoring Transmission to Service..................................................................................................... 0 STRUCTURES........................................................................................................................................ 77 STRUCTURAL COMPONENTS......................................................................................................................... 79 LADDERS................................................................................................................................... 79 Installation.......................................................................................................................... 80 Removal............................................................................................................................... 80 RIGHT HAND DECK........................................................................................................................... 80 Removal............................................................................................................................... 80 Installation.......................................................................................................................... 80 CENTER AND LEFT HAND DECK COMPONENTS...................................................................................................... 81 FUEL TANK................................................................................................................................. 82 Removal............................................................................................................................... 82 Installation.......................................................................................................................... 82 DUMP BODY..................................................................................................................................... 83 Removal................................................................................................................................... 83 Installation.............................................................................................................................. 84 BODY PADS................................................................................................................................. 85 Adjustment............................................................................................................................ 86 BODY GUIDE................................................................................................................................ 86 BODY-UP RETENTION CABLE................................................................................................................... 86 BODY POSITION INDICATOR................................................................................................................... 87 ROCK EJECTORS............................................................................................................................. 87 Inspection............................................................................................................................ 87 HOIST LIMIT SWITCH........................................................................................................................ 87 BODY UP SWITCH............................................................................................................................ 87 ENGINE............................................................................................................................................ 89 POWER MODULE.................................................................................................................................. 91 PREPARATION............................................................................................................................... 91 Removal............................................................................................................................... 91 Installation.......................................................................................................................... 95 COOLING SYSTEM................................................................................................................................ 97 COOLING SYSTEM DESCRIPTION................................................................................................................ 97 RADIATOR.................................................................................................................................. 98 Removal............................................................................................................................... 98 Service...............................................................................................................................100 Installation..........................................................................................................................100 RADIATOR FILLING PROCEDURE............................................................................................................100 POWER TRAIN...................................................................................................................................101 ALTERNATOR REMOVAL PROCEDURE..............................................................................................................101 ENGINE ALTERNATOR MATING..............................................................................................................103 Measuring Procedure...............................................................................................................103 Joining Alternator and Engine.....................................................................................................105 ENGINE....................................................................................................................................106 Removal...............................................................................................................................106 Installation..........................................................................................................................106 AIR FILTRATION SYSTEM.........................................................................................................................107 AIR CLEANER...............................................................................................................................107 Operation.............................................................................................................................107 General Service Information...........................................................................................................107 MAIN FILTER ELEMENT.......................................................................................................................107 Removal...............................................................................................................................107 Installation..........................................................................................................................108 SAFETY FILTER ELEMENT.....................................................................................................................109 Removal...............................................................................................................................109 Installation..........................................................................................................................109 AIR INTAKE TROUBLESHOOTING................................................................................................................109 AIR CLEANER ASSEMBLY CLEANING.............................................................................................................109 Main Filter Cleaning..................................................................................................................109 Precleaner Section Cleaning...........................................................................................................110 FAN CLUTCH....................................................................................................................................113 REMOVAL & INSTALLATION TOOLING............................................................................................................113 FAN CLUTCH - DISASSEMBLY..................................................................................................................116 CLEANING AND INSPECTION...................................................................................................................126 ASSEMBLY - FAN CLUTCH.....................................................................................................................130 TEST PROCEDURE............................................................................................................................144 ELECTRICAL SYSTEM (24VDC NON-PROPULSION...........................................................................................................145 24VDC ELECTRIC SUPPLY SYSTEM..................................................................................................................147 ELECTRICAL SYSTEM DESCRIPTION.............................................................................................................147 BATTERY...............................................................................................................................147 Maintenance and Service...............................................................................................................147 Troubleshooting.......................................................................................................................147 BATTERY CHARGING SYSTEM (Niehoff).........................................................................................................149 General Description...................................................................................................................149 TROUBLESHOOTING PROCEDURES (On-Truck).............................................................................................149 Preliminary Checks............................................................................................................150 Test Setup....................................................................................................................150 Test Procedure................................................................................................................150 Regulator Bypass Test.........................................................................................................151 ON VEHICLE TROUBLESHOOTING GUIDE - SELF ENERGIZED ALTERNATOR......................................................................152 ALTERNATOR ELECTRICAL CONDITION - Low Voltage - High Voltage - No Voltage.....................................................152 PRELIMINARY PROCEDURES........................................................................................................152 LOW VOLTAGE OUTPUT........................................................................................................152 HIGH VOLTAGE OUTPUT.......................................................................................................152 NO VOLTAGE OUTPUT.........................................................................................................152 TOOLS AND EQUIPMENT:..........................................................................................................152 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:..............................................................................152 Low Maintenance Types:....................................................................................................152 Maintenance Free types:...................................................................................................153 High-Cycle Maintenance Free Types:........................................................................................153 DEFINITIONS...................................................................................................................153 ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized.......................................................................154 NO ALTERNATOR OUTPUT......................................................................................................154 STATIC TEST - ENGINE OFF, KEY ON, BATTERY SWITCH ON...................................................................154 GO TO ALTERNATOR”.....................................................................................................154 GO TO “R” TERMINAL ON ALTERNATOR......................................................................................154 RE-TEST CHARGING CIRCUIT FOR OPERATION with ENGINE RUNNING............................................................154 GO TO REGULATOR (IF REQUIRED).........................................................................................155 GO TO REGULATOR CONNECTOR ON ALTERNATOR...............................................................................155 MAINTENANCE...............................................................................................................157 Prelube System Operation Checks.......................................................................................157 Check Valve...........................................................................................................157 Timer Solenoid........................................................................................................157 24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE).............................................................................................156 OPERATION.............................................................................................................................156 Pressure Switch.......................................................................................................................157 Check Valve...........................................................................................................................157 Timer Solenoid........................................................................................................................157 Troubleshooting Prelube Starter Circuit...............................................................................................158 24 VDC ELECTRIC START SYSTEM..............................................................................................................160 CRANKING MOTORS.......................................................................................................................160 OPERATION.........................................................................................................................160 Removal...........................................................................................................................160 Installation......................................................................................................................160 CRANKING MOTOR TROUBLESHOOTING........................................................................................................161 Preliminary Inspection............................................................................................................161 No-Load Test......................................................................................................................161 Interpreting Results of Tests.....................................................................................................161 Disassembly.......................................................................................................................162 Cleaning and Inspection...........................................................................................................164 Armature Servicing................................................................................................................164 Field Coil Checks.................................................................................................................164 Field Coil Removal................................................................................................................164 Solenoid Checks.......................................................................................................................165 Test..............................................................................................................................165 Assembly..........................................................................................................................166 Bearing Replacement:..............................................................................................................166 Motor Assembly:...................................................................................................................166 Pinion Clearance..................................................................................................................167 MAGNETIC SWITCH...................................................................................................................167 Installation......................................................................................................................167 Coil Test.........................................................................................................................168 24 VDC ELECTRICAL SYSTEM COMPONENTS...........................................................................................................169 PASSENGER SEAT BASE COMPARTMENT...........................................................................................................169 COMPONENTS................................................................................................................................169 TAIL LIGHT RESISTOR DIODE ASSEMBLIES..................................................................................................169 INCLINOMETER..........................................................................................................................169 BRAKE WARNING BUZZER (BWB)............................................................................................................169 LUBRICATION SYSTEM TIMER..............................................................................................................169 5 MINUTE IDLE TIMER COMPONENTS........................................................................................................169 5 Minute Idle Timer...................................................................................................................171 5 Minute Idle Relay...................................................................................................................171 5 Minute Idle Contactor...............................................................................................................171 5 MINUTE IDLE CIRCUIT TEST............................................................................................................171 DATA STORE SWITCH.....................................................................................................................171 KOMATSU ENGINE QUANTUM CONNECTOR......................................................................................................171 KOMATSU ENGINE CENSE CONNECTOR........................................................................................................171 STATEX III PROPULSION SYSTEM DIAGNOSTIC CONNECTOR.....................................................................................171 SPARE CONNECTOR LOCATION..............................................................................................................171 ALARM INDICATING DEVICE (AID) SYSTEM......................................................................................................172 Diode Matrix (Without Sound)..........................................................................................................172 Diode Matrix (With Sound).............................................................................................................172 Hot Switch Inverter...................................................................................................................173 Hot Switch Inverter Card (Slot 4) (Not Used)..........................................................................................173 Temperature...........................................................................................................................173 Oil Level.............................................................................................................................173 Temperature and Latch.................................................................................................................173 Coolant Level/Flasher.................................................................................................................173 Lamp Test.............................................................................................................................173 BATTERY EQUALIZER BOX.....................................................................................................................174 Troubleshooting.......................................................................................................................174 BODY-UP SWITCH............................................................................................................................175 Adjustment............................................................................................................................175 Service...............................................................................................................................175 HOIST LIMIT SWITCH........................................................................................................................175 Adjustment............................................................................................................................175 Service...............................................................................................................................175 24 VOLT RELAY AND DIODE BOARDS............................................................................................................176 RELAY BOARDS..........................................................................................................................176 Description...........................................................................................................................176 SERVICE...............................................................................................................................177 To replace a relay:...................................................................................................................177 To replace a circuit breaker:.........................................................................................................177 To replace a circuit panel card.......................................................................................................178 RELAY BOARD COMPONENTS................................................................................................................178 DIODE BOARD 1.........................................................................................................................181 Diode Testing.........................................................................................................................181 CIRCUIT BREAKERS..........................................................................................................................182 VEHICLE HEALTH MONITORING SYSTEM (VHMS).......................................................................................................183 VHMS BASIC FEATURES.......................................................................................................................183 Gather Data...........................................................................................................................183 Convert and Record Data...............................................................................................................184 Communicate Data to Off-Board Systems.................................................................................................184 USING THE VHMS SYSTEM.....................................................................................................................185 Turning the VHMS System ON............................................................................................................185 Normal VHMS Operation.................................................................................................................186 Turning the VHMS System OFF...........................................................................................................186 Downloading from the VHMS controller..................................................................................................186 VHMS DATA ITEMS...........................................................................................................................187 Fault Codes...........................................................................................................................187 Machine History.......................................................................................................................187 VHMS History..........................................................................................................................187 Snapshots.............................................................................................................................187 Manual Snapshots......................................................................................................................189 Trends................................................................................................................................189 Histogram (Load Map) Data.............................................................................................................191 Haul Cycle Data.......................................................................................................................191 Alarm and Snapshot Triggers...........................................................................................................193 Satellite Features....................................................................................................................195 VHMS DIAGNOSTIC FEATURES..................................................................................................................195 Fault History.........................................................................................................................195 VHMS LED Digits.......................................................................................................................195 VHMS COMPONENTS...........................................................................................................................196 VHMS Controller.......................................................................................................................196 Removal...............................................................................................................................196 Installation..........................................................................................................................197 OrbComm Controller....................................................................................................................197 Removal...............................................................................................................................197 Installation..........................................................................................................................198 Interface Module......................................................................................................................198 Removal...............................................................................................................................199 Installation..........................................................................................................................199 Temperature Sensors...................................................................................................................200 Pressure Sensors......................................................................................................................201 VHMS SOFTWARE.................................................................................................................................203 NECESSARY SOFTWARE........................................................................................................................203 NECESSARY TOOLS...........................................................................................................................203 VHMS TOOL BOX INSTALLATION................................................................................................................204 VHMS SETTING TOOL INSTALLATION............................................................................................................204 VHMS INITIALIZATION PROCEDURE.............................................................................................................204 Preliminary Checks....................................................................................................................204 Initialization Steps..................................................................................................................205 Select Operation......................................................................................................................205 VHMS Setting Function.................................................................................................................205 Machine Information Setting(1)........................................................................................................205 Machine Information Setting(2)........................................................................................................205 Date & Time Setting...................................................................................................................206 GCC Setting...........................................................................................................................206 Setting Summary.......................................................................................................................206 VHMS SNAPSHOT PROCEDURE...................................................................................................................207 VHMS DOWNLOAD.............................................................................................................................207 VHMS FTP UPLOAD...........................................................................................................................208 LOCATION OF DOWNLOAD FILES................................................................................................................209 INSTALLING FLASHBURN PROGRAM..............................................................................................................210 INSTALLING APPLICATION CODE INTO INTERFACE MODULE.........................................................................................210 INSTALLING VHMS WATCHER PROGRAM...........................................................................................................211 INSTALLING VHMS WATCHER DATA FILES........................................................................................................211 WHEN REPLACING A VHMS CONTROLLER..........................................................................................................211 To Set: Date & Time; Satellite; Payload Meter.........................................................................................214 Review Setting Information............................................................................................................215 VHMS CHECKOUT & TROUBLESHOOTING...............................................................................................................217 VHMS CHECKOUT PROCEDURE...................................................................................................................217 General...............................................................................................................................217 Structure and Purpose.................................................................................................................218 Necessary Equipment:..................................................................................................................218 VHMS SYSTEM CHECKOUT......................................................................................................................218 Preliminary...........................................................................................................................218 Checking Inputs To The Interface Module...............................................................................................219 Checking Outputs From The Interface Module............................................................................................222 VHMS CONTROLLER CHECKOUT..................................................................................................................222 TROUBLESHOOTING...........................................................................................................................223 Communications Networks...............................................................................................................223 Coaxial Cable.........................................................................................................................223 VHMS COMPONENTS...........................................................................................................................224 VHMS Controller.......................................................................................................................224 OrbComm Controller....................................................................................................................225 Interface Module......................................................................................................................225 FAULT CODES...............................................................................................................................226 Fault History.........................................................................................................................226 VHMS LED Display Fault Codes..........................................................................................................227 Chassis Fault Codes...................................................................................................................228 Engine Fault Codes....................................................................................................................231 FAULT TREE ANALYSIS.......................................................................................................................237 Unable to connect to VHMS from laptop PC..............................................................................................237 Flashing Error Code N4-23 (PLM III Communications Fault)..............................................................................238 Flashing Error Code N4-22 (Engine Communications Fault)...............................................................................239 No Data Received By WebCARE...........................................................................................................240 Coaxial Cable Troubleshooting.........................................................................................................241 VHMS FORMS....................................................................................................................................243 VHMS INITIALIZATION CHECK LIST............................................................................................................243 VHMS DATA DOWNLOAD........................................................................................................................244 VHMS INITIALIZATION FORM..................................................................................................................244 VHMS INITIALIZATION CHECK LIST............................................................................................................245 VHMS INITIALIZATION FORM..................................................................................................................247 ELECTRICAL PROPULSION COMPONENTS..................................................................................................................249 ELECTRICAL PROPULSION COMPONENTS..............................................................................................................251 GENERAL SYSTEM DESCRIPTION................................................................................................................251 CONTROL SYSTEM............................................................................................................................251 System Operation......................................................................................................................252 FL275 Panel...........................................................................................................................253 CARD REPLACEMENT..........................................................................................................................254 Removal...............................................................................................................................254 Installation..........................................................................................................................254 Card Repair...........................................................................................................................254 Panel Wiring..........................................................................................................................254 COMPUTER DESCRIPTION......................................................................................................................255 Microprocessor........................................................................................................................255 Download Capability...................................................................................................................255 SOFTWARE..................................................................................................................................255 Base Monitor Program..................................................................................................................255 Runtime Monitor Program - OBJ Running Code............................................................................................255 Configuration Software - CFG..........................................................................................................256 PTU - Portable Test Unit Code.........................................................................................................256 System Regulation.....................................................................................................................256 Propulsion............................................................................................................................257 Retarding.............................................................................................................................257 2-DIGIT DISPLAY PANEL.....................................................................................................................258 The Coded Number......................................................................................................................258 Events................................................................................................................................258 Frames................................................................................................................................259 Windows...............................................................................................................................259 System Categories.....................................................................................................................259 Limits On Resetting Faults............................................................................................................259 NA Faults.............................................................................................................................260 Event Sequence........................................................................................................................260 Resetting Events......................................................................................................................260 Event Descriptions....................................................................................................................260 Subcode Descriptions..................................................................................................................260 2-DIGIT DISPLAY PANEL CODES...............................................................................................................261 2-DIGIT DISPLAY PANEL SUBCODES............................................................................................................268 PORTABLE TEST UNIT (PTU)..................................................................................................................271 DESCRIPTION...........................................................................................................................271 Operational Hints.................................................................................................................271 Hard Disk Space Requirements......................................................................................................272 SOFTWARE INSTALLATION ON PTU..........................................................................................................272 PTU/Truck Communication Problems..................................................................................................273 THE MAIN MENU.........................................................................................................................274 “Quit Menu”.......................................................................................................................274 “PTU Talk To Truck”...............................................................................................................274 “View PTU Saved Files”............................................................................................................274 “List Stat Data Files”............................................................................................................274 “Truck Setup (CFG)”...............................................................................................................274 “Select Truck Setup”..............................................................................................................274 “Update CFG Version”..............................................................................................................274 “Change PTU Password”.............................................................................................................274 CONFIGURATION (CFG) FILE CONVERSION...................................................................................................276 Conversion Procedure..............................................................................................................276 Convert old CFG files for new software:...........................................................................................277 STATEX CONFIGURATION FILES............................................................................................................280 “0) Source Directory: . . .”......................................................................................................280 “1) Select A Truck Configuration . . .”...........................................................................................281 “2) View Truck Configuration: Data Curves . . .”..................................................................................282 “3) Change/View Serial and Model Numbers . . .”...................................................................................283 “4) View Options . . .”...........................................................................................................283 “5) Change/View Truck Specifics . . .”............................................................................................285 “6) Change/View Overspeeds . . .”.................................................................................................287 “7) Save a Truck Configuration, filename: . . .”..................................................................................288 “8) Save Directory: . . .”........................................................................................................289 “CHANGE PTU PASSWORD”.................................................................................................................290 PROGRAMMING THE TRUCK.................................................................................................................291 Connect PTU to the Truck..........................................................................................................291 Select Configuration File.........................................................................................................291 Activate The PTU Mode.............................................................................................................291 Check Object Code Version.........................................................................................................292 Download Configuration Files......................................................................................................293 Date And Time.....................................................................................................................294 Event Data........................................................................................................................295 Statistical Data..................................................................................................................297 “View Counters”...................................................................................................................297 “View Profiles”...................................................................................................................297 “Upload Statistical Data To A File”...............................................................................................297 Statistical Data Codes - Counters.................................................................................................298 STATISTICAL DATA CODES - COUNTERS.....................................................................................................299 STATISTICAL DATA CODES - PROFILES.....................................................................................................304 TRUCK SPECIFIC INFORMATION............................................................................................................308 Temporary Truck Settings..........................................................................................................309 MISCELLANEOUS FEATURES................................................................................................................310 Saving Data.......................................................................................................................310 PTU Abbreviations.................................................................................................................311 Other Menu Selections.............................................................................................................311 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS............................................................................................312 ALTERNATOR............................................................................................................................312 ELECTRIC WHEEL MOTORS.................................................................................................................312 RETARDING GRIDS.......................................................................................................................312 ELECTRONIC ACCELERATOR AND RETARD PEDALS..............................................................................................312 Removal...........................................................................................................................312 Installation......................................................................................................................312 Disassembly.......................................................................................................................313 Reassembly........................................................................................................................313 COOLING BLOWER WARNING SYSTEM.........................................................................................................314 Operation.........................................................................................................................314 Test..............................................................................................................................314 Removal...........................................................................................................................314 Installation......................................................................................................................314 ELECTRICAL CONTROL CABINET................................................................................................................315 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS....................................................................................320 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III........................................................................................321 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE...............................................................................................323 GENERAL INFORMATION.......................................................................................................................325 COMMUNICATIONS PORT CHECK.................................................................................................................326 PTU Hookup............................................................................................................................326 1.0 SEQUENCE TESTS - (Engine not running).................................................................................................328 1.1 Throttle System Check and Adjustment..............................................................................................329 1.1.1 Electronic Throttle System. (Williams electronic foot pedal, Dresser ACC/RET Interface Circuit and Pedal Detector Card).....329 1.1.2 Electronic Throttle System (Fuel Saver System)..............................................................................330 1.2 Retard System Check and Adjustment................................................................................................332 1.2.1 Williams Electronic Retard Pedal and Dresser ACC/RET or RET Interface Box...................................................332 1.2.2 Electronic Retard Pedal; Fuel Saver Equipped Trucks and Current Production..................................................333 1.3 Reverser and Propulsion Contactors Check..........................................................................................335 1.4 Propulsion Lockout Test (DDEC & MTU Engine Trucks Only)...........................................................................336 1.5 Retard Contactors Operation Check.................................................................................................337 1.6 Ground Fault Sensing Check........................................................................................................337 1.7 Ground Fault in Retard Operation Check............................................................................................337 1.8 Override Operation Check..........................................................................................................338 1.9 Anti-Reversal Function (AR) Check.................................................................................................339 1.10 Overspeed Retard Operation Check.................................................................................................339 1.11 Hoist Interlock Operation Check..................................................................................................340 1.12 Motor Blower Fault Light Operation Check.........................................................................................341 2.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL..................................................................................342 2.1 Setup Manual Digital Input/Output Test on PTU.....................................................................................342 2.2 Digital Input Checks..............................................................................................................343 2.3 Digital Output Checks.............................................................................................................345 3.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL..........................................................................................348 3.1 Setup Analog Input Monitor Screen on PTU..........................................................................................348 3.2 Analog Input Checks...............................................................................................................349 3.3 Frequency Input Checks............................................................................................................356 4.0 SPEED EVENT CHECKS....................................................................................................................358 4.1 Single Speed Overspeed Truck - Overspeed Settings Check...........................................................................359 4.2 Two Speed Overspeed Truck (Empty Truck) - Overspeed Settings Check................................................................359 4.3 Two Speed Overspeed Truck (Loaded Truck) - Overspeed Settings Check...............................................................359 4.4 Other Speed Events Checks.........................................................................................................359 5.0 RETARD SPEED CONTROL SYSTEM CHECK.....................................................................................................361 5.1 Overspeed Pickup and Dropout Check................................................................................................361 5.2 Retard Pot Maximum Setting Check..................................................................................................362 5.3 Retard Pot Minimum Setting Check..................................................................................................362 5.4 Accelerator Pedal Override of Retard Speed Control................................................................................362 6.0 LOAD TEST USING TRUCK RETARD GRIDS....................................................................................................363 6.1 Load Test.........................................................................................................................364 7.0 MOTOR FIELD CURRENT CHECK IN RETARDING................................................................................................365 7.1 Retard Check......................................................................................................................365 8.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT...........................................................................................366 8.1 Brake System Interlocks Check.....................................................................................................366 8.2 Blower Loss Pressure Switch Adjustment............................................................................................367 8.3 SYNC Transformer Checkout.........................................................................................................367 8.4 Power Contactor Position Sensor Adjustment........................................................................................367 8.5 Battery Boost Adjustment..........................................................................................................368 8.6 Isolation amplifier & voltage module test.........................................................................................368 8.6.1 Voltage Measuring Module Test (VMM1 and VMM2)...............................................................................368 8.6.2 ISOA3, ISOA4, ISOA5, ISOA6, ISOA-7, and ISOA-8 Test.........................................................................369 8.7 Motor Rotation Test...............................................................................................................369 8.8 Ground Fault Checks...............................................................................................................370 9.0 MISCELLANEOUS CHARTS..................................................................................................................371 9.1 Wheel Motor Gear Ratios...........................................................................................................371 9.2 Maximum Allowable Truck Speeds....................................................................................................372 9.3 Engine Options....................................................................................................................373 DRIVE AXLE, SPINDLE AND WHEELS....................................................................................................................375 TIRES AND RIMS................................................................................................................................377 FRONT TIRES AND RIMS......................................................................................................................377 Removal...............................................................................................................................377 Installation..........................................................................................................................378 REAR TIRES AND RIMS.......................................................................................................................379 Removal...............................................................................................................................379 Installation..........................................................................................................................380 RIM.......................................................................................................................................381 RIM AND TIRE PREPARATION..............................................................................................................381 Tire Removal..........................................................................................................................381 LUBRICANTS............................................................................................................................382 TIRE INSTALLATION.....................................................................................................................382 FRONT WHEEL HUB AND SPINDLE...................................................................................................................385 WHEEL HUB AND SPINDLE ASSEMBLY............................................................................................................385 Removal...............................................................................................................................385 Spindle Pusher Tool Usage.............................................................................................................386 Installation..........................................................................................................................387 Disassembly...........................................................................................................................389 Cleaning and Inspection...............................................................................................................389 Assembly..............................................................................................................................390 Wheel Bearing Adjustment (Tire Removed)...............................................................................................392 Wheel Bearing Adjustment (Tire mounted)...............................................................................................392 STEERING CYLINDERS AND TIE ROD............................................................................................................394 Spherical Bearing Wear Limits.........................................................................................................394 Removal...............................................................................................................................395 Installation..........................................................................................................................395 Bearing Replacement...................................................................................................................395 TOE-IN ADJUSTMENT.........................................................................................................................397 REAR AXLE HOUSING ATTACHMENT..................................................................................................................399 PIVOT PIN.................................................................................................................................399 Removal...............................................................................................................................399 Installation..........................................................................................................................399 PIVOT EYE BEARING.........................................................................................................................400 Disassembly...........................................................................................................................400 Assembly..............................................................................................................................400 PIVOT EYE REPAIR..........................................................................................................................401 Removal...............................................................................................................................401 Disassembly...........................................................................................................................401 Assembly..............................................................................................................................401 Installation..........................................................................................................................401 ANTI-SWAY BAR.............................................................................................................................402 Removal...............................................................................................................................402 Installation..........................................................................................................................402 Disassembly...........................................................................................................................402 Cleaning and Inspection...............................................................................................................402 Assembly..............................................................................................................................402 REAR AXLE HOUSING.............................................................................................................................403 REAR AXLE HOUSING.........................................................................................................................403 Removal...............................................................................................................................403 Installation..........................................................................................................................403 WHEEL MOTOR...............................................................................................................................403 Removal...............................................................................................................................403 Cleaning and Inspection...............................................................................................................404 Installation..........................................................................................................................404 Maximum Capscrew Usage................................................................................................................404 SUSPENSIONS.......................................................................................................................................405 FRONT SUSPENSION..............................................................................................................................407 Removal...................................................................................................................................407 Installation..............................................................................................................................408 MAXIMUM CAPSCREW USAGE....................................................................................................................409 “TURN-OF-THE-NUT” Tightening Procedure....................................................................................................410 MINOR REPAIR ONLY (Lower Bearing Structure & Seals).......................................................................................411 Bearing Structure Removal.............................................................................................................411 Bearing Structure Installation........................................................................................................411 MAJOR SUSPENSION REBUILD..................................................................................................................412 Disassembly...........................................................................................................................412 Assembly..............................................................................................................................413 PRESSURE TEST.............................................................................................................................414 REAR SUSPENSIONS..............................................................................................................................415 Removal...................................................................................................................................415 Installation..............................................................................................................................417 Disassembly...............................................................................................................................419 Cleaning and Inspection...................................................................................................................419 Assembly..................................................................................................................................419 PRESSURE TEST.............................................................................................................................420 OILING AND CHARGING PROCEDURE.................................................................................................................421 GENERAL...................................................................................................................................421 EQUIPMENT LIST............................................................................................................................421 HYDRAIR® CHARGING KIT.....................................................................................................................421 Installation of Charging Kit..........................................................................................................421 Removal of Charging Kit...............................................................................................................422 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS.........................................................................................422 FRONT SUSPENSION..........................................................................................................................423 Front Suspension Oiling...............................................................................................................423 Front Suspension Nitrogen Charging....................................................................................................424 REAR SUSPENSION...........................................................................................................................425 Rear Suspension Oiling................................................................................................................425 Rear Suspension Nitrogen Charging.....................................................................................................426 OIL AND NITROGEN SPECIFICATIONS CHART.....................................................................................................428 BRAKE CIRCUIT.....................................................................................................................................429 BRAKE CIRCUIT.................................................................................................................................431 SERVICE BRAKE CIRCUIT OPERATION...........................................................................................................431 SECONDARY BRAKING AND AUTOMATIC APPLY.....................................................................................................433 PARKING BRAKE CIRCUIT.....................................................................................................................433 Normal Operation (key switch on, engine running)......................................................................................433 BRAKE LOCK CIRCUIT........................................................................................................................434 WARNING CIRCUIT...........................................................................................................................434 BRAKE CIRCUIT COMPONENT SERVICE...............................................................................................................437 BRAKE VALVE...............................................................................................................................437 Rebuild Criteria......................................................................................................................437 Removal...............................................................................................................................437 DISASSEMBLY...........................................................................................................................440 Cleaning and Inspection...........................................................................................................442 ASSEMBLY..............................................................................................................................442 Actuator Base Threaded Inserts....................................................................................................442 Boot and Cap......................................................................................................................442 Valve Body Seal Installation......................................................................................................443 Regulator Sleeve O-Ring Installation..............................................................................................443 Actuator Plunger O-ring Installation..............................................................................................443 Assembly of Valve.................................................................................................................444 DIFFERENTIAL PRESSURE SWITCH..........................................................................................................445 Disassembly.......................................................................................................................445 Cleaning and Inspection...........................................................................................................445 Assembly..........................................................................................................................445 VALVE BENCH TEST AND ADJUSTMENT.......................................................................................................446 Test Set Up Procedure.............................................................................................................447 Brake Valve Output Pressure Adjustment............................................................................................447 Differential Pressure Switch Test.................................................................................................447 Final Test and Adjustment.........................................................................................................448 Installation Of Brake Pedal Actuator Assembly to Brake Valve......................................................................449 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal)..................................................450 Installation of Retard Pedal To Brake Pedal.......................................................................................450 HYDRAULIC BRAKE ACCUMULATORS..............................................................................................................451 Brake Accumulator Bleed Down Procedure................................................................................................451 Removal...............................................................................................................................451 Installation..........................................................................................................................451 Disassembly...........................................................................................................................451 Cleaning and Inspection...............................................................................................................452 Assembly..............................................................................................................................453 Charging Procedure....................................................................................................................454 BRAKE MANIFOLD............................................................................................................................455 Removal...............................................................................................................................455 Removal...............................................................................................................................455 Installation..........................................................................................................................456 Disassembly...........................................................................................................................456 Cleaning and Inspection...............................................................................................................456 Assembly..............................................................................................................................456 BRAKE CIRCUIT CHECK-OUT PROCEDURE.............................................................................................................457 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING.............................................................................................463 EQUIPMENT REQUIRED........................................................................................................................459 INITIAL SYSTEM SET-UP.....................................................................................................................460 PARKING BRAKE.............................................................................................................................460 BRAKE SYSTEM CHECK-OUT....................................................................................................................460 Failure Modes Check-Out...................................................................................................................461 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.............................................................................467 ROCKWELL WHEEL SPEED FRONT DISC BRAKES........................................................................................................469 BRAKE CALIPER.............................................................................................................................469 Caliper Removal.......................................................................................................................469 Installation..........................................................................................................................470 Disassembly...........................................................................................................................471 Assembly..............................................................................................................................471 Cleaning and Inspection...............................................................................................................472 BRAKE LINING..............................................................................................................................473 Replacement...........................................................................................................................473 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE...................................................................................474 SAFETY PRECAUTIONS....................................................................................................................474 Front Brake Conditioning..............................................................................................................474 BRAKE BLEEDING PROCEDURES.................................................................................................................475 ROCKWELL ARMATURE SPEED REAR DISC BRAKES......................................................................................................477 REAR BRAKES...............................................................................................................................477 CALIPER, DISC, AND PARKING BRAKE..........................................................................................................477 Caliper, Disc, and Parking Brake Removal..............................................................................................477 Caliper, Disc, And Parking Brake Installation.........................................................................................478 CALIPER, DISC, & PARKING BRAKE REMOVAL [For trucks equipped with one-piece adapter (16, Figure 6-3A)].................................480 Caliper, Disc, And Parking Brake Installation.........................................................................................481 CALIPER PISTON............................................................................................................................482 Piston Assembly Removal...............................................................................................................482 Inspection............................................................................................................................482 Piston Assembly Installation..........................................................................................................482 FUNCTIONAL TEST OF PISTON ASSEMBLY....................................................................................................483 Return Spring Force...................................................................................................................483 Built-In Clearance....................................................................................................................483 Grip Force............................................................................................................................484 Grip Force Measurement................................................................................................................485 Spring Force Measurement..............................................................................................................486 Disassembly of Piston Assembly........................................................................................................487 Assembly of Piston Assembly...........................................................................................................488 BENCH TEST................................................................................................................................488 BRAKE LINING..............................................................................................................................489 Replacement...........................................................................................................................489 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.........................................................................................492 General...............................................................................................................................492 Safety Precautions....................................................................................................................492 Rear Brake Conditioning...............................................................................................................493 BRAKE BLEEDING PROCEDURE..................................................................................................................494 ROCKWELL DISC PARKING BRAKE...................................................................................................................495 PARK BRAKE CALIPER........................................................................................................................495 Removal...............................................................................................................................495 Installation..........................................................................................................................496 Parking Brake Adjustment..............................................................................................................496 Park Brake Caliper Disassembly........................................................................................................498 Cleaning and Inspection...............................................................................................................498 Park Brake Caliper Assembly...........................................................................................................499 PARK BRAKE LINING REPLACEMENT.............................................................................................................500 PARK BRAKE BURNISH PROCEDURE..............................................................................................................500 Lining Conditioning...................................................................................................................500 BRAKE BLEEDING PROCEDURE..................................................................................................................500 HYDRAULIC SYSTEM..................................................................................................................................501 HYDRAULIC SYSTEM..............................................................................................................................503 HYDRAULIC SYSTEM OPERATION................................................................................................................503 COMPONENT DESCRIPTION.....................................................................................................................504 HYDRAULIC SYSTEM COMPONENT REPAIR.............................................................................................................507 HOIST PUMP................................................................................................................................507 Removal...............................................................................................................................507 Installation..........................................................................................................................508 Disassembly...........................................................................................................................509 INSPECTION OF PARTS...................................................................................................................511 Assembly..............................................................................................................................512 AXLE BLOWER PUMP..........................................................................................................................517 AXLE BLOWER MOTOR.........................................................................................................................531 Hand Wheel Control....................................................................................................................538 HYDRAULIC TANK............................................................................................................................540 Filling Instructions..................................................................................................................540 Removal...............................................................................................................................541 Installation..........................................................................................................................541 HYDRAULIC TANK STRAINERS..............................................................................................................541 Removal...........................................................................................................................541 Inspect and Clean.................................................................................................................542 Installation......................................................................................................................542 STEERING CIRCUIT..............................................................................................................................543 STEERING CIRCUIT OPERATION................................................................................................................543 COMPONENT DESCRIPTION.....................................................................................................................544 Steering Depressurization Solenoid Valve..............................................................................................545 Pilot-to-open Check Valve.............................................................................................................545 Pilot-to-open Check Valve Control Solenoid............................................................................................545 Steering Pump Compensator Vent Solenoid Valve.........................................................................................544 Steering Control Unit.................................................................................................................545 HYDRAULIC TANK........................................................................................................................546 FLOW AMPLIFIER........................................................................................................................546 BLEED DOWN MANIFOLD...................................................................................................................556 ACCUMULATORS..........................................................................................................................557 Low Precharge Warning Switch......................................................................................................557 HIGH PRESSURE FILTER..................................................................................................................557 STEERING/BRAKE PUMP...................................................................................................................557 STEERING CIRCUIT COMPONENT REPAIR.............................................................................................................559 BLEED DOWN MANIFOLD.......................................................................................................................559 Removal...............................................................................................................................559 Installation..........................................................................................................................559 ACCUMULATOR...............................................................................................................................560 Removal...............................................................................................................................560 Installation..........................................................................................................................561 Disassembly...........................................................................................................................561 Cleaning and Inspection...............................................................................................................561 Assembly..............................................................................................................................562 LEAK TESTING..........................................................................................................................563 STEERING ACCUMULATOR CHARGING PROCEDURE...............................................................................................564 Temperature During Precharge......................................................................................................567 ACCUMULATOR STORAGE PROCEDURES........................................................................................................568 INstructions For Storing Bladder Accumulators.....................................................................................568 Instructions For Installing A Bladder Accumulator That Was In A Parts Warehouse Or In Storage.....................................568 Bladder Storage Procedures........................................................................................................569 FLOW AMPLIFIER............................................................................................................................570 Removal...............................................................................................................................570 Installation..........................................................................................................................570 Disassembly...........................................................................................................................570 Reassembly............................................................................................................................573 STEERING CONTROL UNIT.....................................................................................................................574 Removal...............................................................................................................................574 Spline Inspection.....................................................................................................................574 Installation..........................................................................................................................574 Disassembly...........................................................................................................................575 Cleaning and Inspection...............................................................................................................576 Assembly..............................................................................................................................576 STEERING CYLINDER.........................................................................................................................580 Disassembly...........................................................................................................................580 Inspection and Cleaning...............................................................................................................580 Assembly..............................................................................................................................580 STEERING CIRCUIT FILTER...................................................................................................................581 FILTER ELEMENT REPLACEMENT............................................................................................................581 Removal...............................................................................................................................582 Installation..........................................................................................................................582 INDICATOR SWITCH......................................................................................................................582 STEERING AND BRAKE PUMP...................................................................................................................582 Removal...............................................................................................................................582 Installation..........................................................................................................................583 Disassembly...........................................................................................................................588 Inspection............................................................................................................................593 Assembly..............................................................................................................................595 HOIST CIRCUIT.................................................................................................................................599 HOIST CIRCUIT OPERATION...................................................................................................................599 COMPONENT DESCRIPTION.....................................................................................................................601 Hydraulic Tank........................................................................................................................601 Hoist Pump............................................................................................................................601 High Pressure Filters.................................................................................................................601 HOIST VALVE...........................................................................................................................602 HOIST PILOT VALVE.....................................................................................................................603 HOIST-UP LIMIT SOLENOID...............................................................................................................603 PILOT OPERATED CHECK VALVE............................................................................................................603 HOIST CONTROLLER......................................................................................................................604 COUNTERBALANCE VALVE MANIFOLD.........................................................................................................605 HOIST SYSTEM OPERATION MODES..............................................................................................................606 FLOAT POSITION OF PILOT VALVE AND BODY ON FRAME (Figure 7-6)..........................................................................606 POWER UP OPERATION (Figure 7-8).......................................................................................................608 HOLD OPERATION (Figure 7-9)...........................................................................................................610 POWER DOWN OPERATION (Figure 7-10)....................................................................................................612 FLOAT OPERATION (Figure 7-11).........................................................................................................614 HOIST CIRCUIT COMPONENT REPAIR................................................................................................................617 HOIST VALVE...............................................................................................................................617 Removal...............................................................................................................................617 Installation..........................................................................................................................617 O-Ring Replacement....................................................................................................................618 INLET SECTION.........................................................................................................................618 Disassembly...........................................................................................................................618 Cleaning and Inspection...............................................................................................................619 Assembly..............................................................................................................................620 SPOOL SECTION.........................................................................................................................620 Disassembly...........................................................................................................................620 Cleaning and Inspection...............................................................................................................622 Assembly..............................................................................................................................622 HOIST PILOT VALVE.........................................................................................................................623 Removal...............................................................................................................................623 Installation..........................................................................................................................623 Disassembly...........................................................................................................................623 Cleaning and Inspection...............................................................................................................625 Assembly..............................................................................................................................625 BODY UP LIMIT SOLENOID....................................................................................................................626 PILOT OPERATED CHECK VALVE................................................................................................................626 HOIST CONTROLLER..........................................................................................................................626 HOIST CYLINDERS...........................................................................................................................627 Removal...............................................................................................................................627 Installation..........................................................................................................................628 Disassembly...........................................................................................................................630 Cleaning and Inspection...............................................................................................................631 ASSEMBLY OF QUILL AND CYLINDER........................................................................................................632 Quill Installation................................................................................................................632 Installation of Check Balls and Plugs in Quill........................................................................................633 Assembly of Cylinder..................................................................................................................634 COUNTERBALANCE MANIFOLD...................................................................................................................635 DISABLED TRUCK DUMPING PROCEDURE..........................................................................................................636 HOOKUP................................................................................................................................636 DUMPING PROCEDURE.....................................................................................................................636 HYDRAULIC CHECKOUT PROCEDURE..................................................................................................................637 PRELIMINARY SET-UP........................................................................................................................637 STEERING AND BRAKE PUMP...................................................................................................................638 SHOCK & SUCTION VALVES....................................................................................................................640 LEAKAGE TESTS.............................................................................................................................641 Steering Control Unit & Flow Amplifier................................................................................................641 Bleeddown Manifold....................................................................................................................641 ACCUMULATOR BLEED DOWN PROCEDURE..........................................................................................................643 TROUBLESHOOTING CHART (Steering Circuit)..................................................................................................644 AXLE BOX BLOWER CIRCUIT ADJUSTMENTS.......................................................................................................650 CHECKING HOIST SYSTEM PRESSURES...........................................................................................................652 HOIST CONTROLLER TROUBLESHOOTING PROCEDURE................................................................................................655 HOIST COUNTERBALANCE VALVE ADJUSTMENT.....................................................................................................657 TROUBLESHOOTING CHART (Hoist Pump)........................................................................................................659 HYDRAULIC SYSTEM FLUSHING PROCEDURE.......................................................................................................661 OIL CLEANLINESS CHECK.....................................................................................................................662 OPTIONS AND SPECIAL TOOLS.........................................................................................................................663 FIRE CONTROL SYSTEM (MANUAL)..................................................................................................................665 Operation.................................................................................................................................665 Inspection and Maintenance................................................................................................................665 Recharging Procedures.....................................................................................................................666 WIGGINS QUICK FILL FUEL SYSTEM................................................................................................................667 FUEL RECEIVER.............................................................................................................................667 TANK BREATHER VALVE.......................................................................................................................668 Removal...............................................................................................................................668 Installation..........................................................................................................................668 Disassembly...........................................................................................................................668 Assembly..............................................................................................................................668 LEFT SIDE FILL............................................................................................................................669 BUCKEYE QUICK FUEL SYSTEM.....................................................................................................................671 FUEL TANK BREATHER VALVE..................................................................................................................671 Maintenance...........................................................................................................................671 Filter Service........................................................................................................................671 Disassembly...........................................................................................................................671 Inspection............................................................................................................................671 Assembly..............................................................................................................................671 FUEL RECEIVER.............................................................................................................................672 ENGINE COOLANT HEATER.........................................................................................................................673 Maintenance...............................................................................................................................673 HEATING ELEMENT...........................................................................................................................673 Removal...................................................................................................................................673 Installation..............................................................................................................................673 THERMOSTAT................................................................................................................................674 Removal...................................................................................................................................674 Installation..............................................................................................................................674 SPECIAL TOOLS.................................................................................................................................675 AIR CONDITIONING SYSTEM.......................................................................................................................681 Environmental Impact......................................................................................................................681 OPERATOR CAB AIR CONDITIONING.............................................................................................................682 PRINCIPLES OF REFRIGERATION...............................................................................................................682 Air Conditioning......................................................................................................................682 Refrigeration - The Act Of Cooling....................................................................................................683 The Refrigeration Cycle...............................................................................................................683 AIR CONDITIONER SYSTEM COMPONENTS.........................................................................................................684 Compressor (Refrigerant Pump).........................................................................................................684 Service Valves........................................................................................................................684 Condenser.............................................................................................................................684 Expansion Block Valve.................................................................................................................685 Evaporator............................................................................................................................685 ELECTRICAL CIRCUIT........................................................................................................................686 Thermostat............................................................................................................................686 Compressor Clutch.....................................................................................................................686 Trinary™ Switch.......................................................................................................................687 SYSTEM SERVICING..........................................................................................................................688 SYSTEM OIL................................................................................................................................689 Handling and Reusing PAG Oil..........................................................................................................689 Oil Quantity..........................................................................................................................689 Replacing Oil After Servicing the System..............................................................................................689 Setting Up a New Compressor...........................................................................................................689 REFRIGERANT...............................................................................................................................690 Recycled Refrigerant..................................................................................................................690 Reclaimed Refrigerant.................................................................................................................690 Refrigerant Quantity..................................................................................................................690 R-134a Refrigerant Containers.........................................................................................................690 SERVICE TOOLS AND EQUIPMENT...............................................................................................................691 Recovery/Recycle Station..............................................................................................................691 Leak Detector.........................................................................................................................691 Service Valves........................................................................................................................692 Vacuum Pump...........................................................................................................................692 Manifold Gauge Set....................................................................................................................693 Installing Manifold Gauge Set.........................................................................................................694 Purging Air From Service Hoses........................................................................................................695 Stabilizing the AC System.............................................................................................................696 SYSTEM PERFORMANCE TEST...................................................................................................................696 SYSTEM LEAK TESTING.......................................................................................................................697 Electronic leak detector..............................................................................................................697 Tracer dyes...........................................................................................................................697 Soap and water........................................................................................................................697 SYSTEM REPAIR.............................................................................................................................698 System Cleaning.......................................................................................................................698 Hoses and Fittings....................................................................................................................698 Lines.................................................................................................................................698 Expansion Valve.......................................................................................................................698 Receiver-Drier........................................................................................................................699 Thermostat............................................................................................................................699 Compressor............................................................................................................................699 Clutch................................................................................................................................699 Servicing the Compressor Clutch.......................................................................................................700 Pulley Removal........................................................................................................................702 Clutch Coil Check.....................................................................................................................702 Pulley Installation...................................................................................................................702 Clutch Assembly Installation..........................................................................................................703 RECOVERING AND RECYCLING THE REFRIGERANT..................................................................................................704 Performing the Recovery Cycle.........................................................................................................704 Performing the Recycling Procedure....................................................................................................704 Evacuating and Charging the AC System.................................................................................................704 EVACUATING THE SYSTEM.....................................................................................................................705 CHARGING THE AC SYSTEM....................................................................................................................706 TROUBLESHOOTING...........................................................................................................................707 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM.......................................................................................715 Pre-Diagnosis Checks..................................................................................................................707 Preparing For Diagnosis...............................................................................................................707 Preliminary Steps.....................................................................................................................707 System Performance Test...............................................................................................................707 Diagnosis Of Gauge Readings And System Performance....................................................................................708 RADIATOR SHUTTERS.............................................................................................................................717 PAYLOAD METER III ™...........................................................................................................................729 INDEX.....................................................................................................................................729 OPERATION SECTION.........................................................................................................................733 Introduction..........................................................................................................................733 Data Summary......................................................................................................................733 Data Gathering....................................................................................................................733 COMPONENT DESCRIPTION.................................................................................................................734 System Diagram....................................................................................................................734 Suspension Pressure Sensors.......................................................................................................734 Inclinometer......................................................................................................................734 Operator Display..................................................................................................................734 Operator Switch...................................................................................................................735 Speed Input.......................................................................................................................735 Body-Up Switch....................................................................................................................735 Brake Lock Switch.................................................................................................................735 Payload Meter.....................................................................................................................735 Communications Ports..............................................................................................................735 Keyswitch Input...................................................................................................................736 Payload Meter Power...............................................................................................................736 Load Lights.......................................................................................................................736 Wiring and Termination............................................................................................................737 TCI Outputs.......................................................................................................................737 OPERATOR’S DISPLAY AND SWITCH.........................................................................................................738 Reading the Speedometer...........................................................................................................738 Reading the Load Display..........................................................................................................738 Using the Operator ID.............................................................................................................738 Using the Load and Ton Counter....................................................................................................738 Total Ton Counter.................................................................................................................738 Total Load Counter................................................................................................................739 Clearing the Counters.............................................................................................................739 Viewing Live Sensor Data..........................................................................................................739 Other Display Messages............................................................................................................739 PAYLOAD OPERATION & CALCULATION.......................................................................................................740 Description of Haul Cycle States..................................................................................................740 Haul Cycle Description............................................................................................................740 Load Calculation..................................................................................................................741 Carry Back........................................................................................................................741 Measurement Accuracy..............................................................................................................741 SOURCES FOR PAYLOAD ERROR.............................................................................................................741 Payload Error.....................................................................................................................741 Loading Conditions................................................................................................................742 Pressure Sensors..................................................................................................................742 Swingloads........................................................................................................................742 Speed and Distance................................................................................................................742 HAUL CYCLE DATA.......................................................................................................................742 Haul Cycle Data...................................................................................................................743 Haul Cycle Warning Flags..........................................................................................................744 M: Haul Cycle Too Long............................................................................................................745 N: Sensor Input Error.............................................................................................................745 Frame Torque Data.................................................................................................................745 Sprung Weight Data................................................................................................................745 Maximum Speed Data................................................................................................................745 Alarm Records.....................................................................................................................745 Fault Code Data...................................................................................................................746 PC SOFTWARE OVERVIEW..................................................................................................................747 PC Overview.......................................................................................................................747 System Configuration..............................................................................................................747 Installing the PLMIII Software....................................................................................................747 DOWNLOADING DATA......................................................................................................................748 PLM III SYSTEM CONFIGURATION..........................................................................................................749 Starting Communications...........................................................................................................749 Displayed Payload Units...........................................................................................................749 Time Units........................................................................................................................749 Connection Menu...................................................................................................................749 Connecting to the Payload Meter...................................................................................................750 Configure the Payload Meter.......................................................................................................750 Setting the Date and Time.........................................................................................................750 Setting the Truck Type............................................................................................................751 Setting the Gauge Display Units...................................................................................................751 Setting the Frame Serial Number...................................................................................................751 Setting the Truck Number..........................................................................................................751 Setting the Komatsu Distributor...................................................................................................751 Setting the Komatsu Customer......................................................................................................751 Clean Truck Tare..................................................................................................................752 Inclinometer Calibration..........................................................................................................752 DATA ANALYSIS.........................................................................................................................753 Creating a Query..................................................................................................................753 Sorting on Truck Unit Number......................................................................................................753 Sorting on Truck Type.............................................................................................................753 Sorting on Date Range.............................................................................................................754 Sorting on Time Range.............................................................................................................754 Payload Detail Screen.............................................................................................................755 Creating Reports..................................................................................................................755 Summary - one page report.........................................................................................................756 Detailed - multi-page report......................................................................................................756 Creating Graphs...................................................................................................................757 Exporting Data....................................................................................................................757 CSV Export........................................................................................................................757 Compressed........................................................................................................................758 Importing Data....................................................................................................................759 Deleting Haul Cycle Records.......................................................................................................759 Viewing Alarms....................................................................................................................760 Deleting Alarm Records............................................................................................................760 TROUBLESHOOTING SECTION...............................................................................................................761 TROUBLESHOOTING...................................................................................................................761 Viewing Active Alarms.........................................................................................................761 Real-Time Data Display........................................................................................................761 Testing the Payload Lights....................................................................................................761 Creating Log Files of Inputs..................................................................................................762 Daily Inspections.............................................................................................................762 Periodic Maintenance..........................................................................................................762 Abnormal Displays at Power-Up.................................................................................................763 No Payload Display When Keyswitch is Turned ON................................................................................764 No Display on Speedometer.....................................................................................................765 No Display on Operator Display................................................................................................765 No Communications With PC.....................................................................................................766 Load Lights Don’t Light During Loading........................................................................................767 Load Lights Remain ON.........................................................................................................768 Load Lights Remain ON During Dumping..........................................................................................768 Display Doesn't Clear When The Load Is Dumped.................................................................................768 Calibration Problems..........................................................................................................769 Alarm 1 - Left Front Pressure High............................................................................................770 Alarm 2 - Left Front Pressure Low.............................................................................................770 Troubleshoot Wiring to Left Front Suspension..................................................................................770 Alarm 3 - Right Front Pressure High...........................................................................................771 Alarm 4 - Right Front Pressure Low............................................................................................771 Troubleshoot Wiring to Right Front Suspension.................................................................................771 Alarm 5 -Left Rear Pressure High..............................................................................................772 Alarm 6 - Left Rear Pressure Low..............................................................................................772 Troubleshoot Wiring to Left Rear Suspension...................................................................................772 Alarm 7 - Right Rear Pressure High............................................................................................773 Alarm 8 - Right Rear Pressure Low.............................................................................................773 Troubleshoot Wiring to Right Rear Suspension..................................................................................773 Alarm 9 - Inclinometer High...................................................................................................774 Alarm 10 - Inclinometer Low...................................................................................................774 Troubleshoot Inclinometer Wiring..............................................................................................774 Alarm 13 - Body Up Input Failure..............................................................................................775 Alarm 16 - Memory Write Failure...............................................................................................776 Alarm 17 - Memory Read Failure................................................................................................776 Alarm 18......................................................................................................................777 Alarm 19......................................................................................................................777 Alarm 22......................................................................................................................777 Operator Switch Doesn't Work..................................................................................................778 Alarm 26 - User Switch Fault - SELECT.........................................................................................778 Alarm 27 - User Switch Fault - SET............................................................................................778 Connector Map.................................................................................................................779 Connectors....................................................................................................................780 PLMIII CHECK OUT PROCEDURE........................................................................................................781 General Description...........................................................................................................781 Tools Required................................................................................................................781 Checkout Procedure............................................................................................................781 PLMIII CHECKOUT PROCEDURE CONFIRMATION........................................................................................785 Flashburn Programming.....................................................................................................785 Confirmation Checklist....................................................................................................787 RESERVE ENGINE OIL SYSTEM.....................................................................................................................789 OPERATORS CAB.....................................................................................................................................795 TRUCK CAB.....................................................................................................................................797 Description...............................................................................................................................797 Removal...............................................................................................................................798 Installation..........................................................................................................................799 CAB DOOR..................................................................................................................................800 Removal...............................................................................................................................800 Installation..........................................................................................................................800 Door Adjustment.......................................................................................................................800 Door Jamb Bolt Adjustment.............................................................................................................800 Door Handle Plunger Adjustment........................................................................................................802 Replace Door Glass....................................................................................................................803 Replace Door Window Regulator.........................................................................................................807 Replace Door Handle or Latch Assembly.................................................................................................807 Door and Door Hinge Seal Replacement..................................................................................................808 Door Opening Seal Removal.............................................................................................................808 Installation..........................................................................................................................808 GLASS REPLACEMENT.........................................................................................................................809 ADHESIVE-BONDED WINDOWS...............................................................................................................809 Replacement Procedure.................................................................................................................809 WINDSHIELD & REAR GLASS...............................................................................................................810 Removal...............................................................................................................................810 Installation..........................................................................................................................811 CAB COMPONENTS................................................................................................................................813 WINDSHIELD WIPERS.........................................................................................................................813 Wiper Motor...........................................................................................................................813 Removal...........................................................................................................................813 Installation......................................................................................................................813 Wiper Arm.............................................................................................................................813 Removal...........................................................................................................................813 Installation......................................................................................................................814 Wiper Linkage.........................................................................................................................814 Removal...........................................................................................................................814 Installation......................................................................................................................814 WINDSHIELD WASHER.........................................................................................................................815 Operation.............................................................................................................................815 Service...............................................................................................................................815 OPERATOR COMFORT..............................................................................................................................817 OPERATORS SEAT............................................................................................................................817 HEATER/AIR CONDITIONER CONTROLS...........................................................................................................818 OPERATION.............................................................................................................................818 HEATER/AIR CONDITIONER................................................................................................................819 OPERATION.........................................................................................................................819 HEATER COMPONENTS.....................................................................................................................819 CIRCUIT BREAKERS..................................................................................................................819 RELAYS............................................................................................................................819 HEATER CORE.......................................................................................................................820 FAN MOTOR AND SPEED CONTROL.......................................................................................................820 Test..............................................................................................................................820 ACTUATORS.........................................................................................................................820 Test..............................................................................................................................820 FILTER............................................................................................................................820 Service...........................................................................................................................820 AIR CONDITIONER COMPONENTS............................................................................................................820 OPERATOR CONTROLS AND EQUIPMENT...............................................................................................................823 STEERING WHEEL AND CONTROLS...............................................................................................................824 STEERING COLUMN.......................................................................................................................825 Removal...........................................................................................................................825 Steering Column Inspection........................................................................................................825 Installation......................................................................................................................825 Horn Button...........................................................................................................................824 Tilt / Telescope Lever................................................................................................................824 Multi-Function Turn Signal Switch.....................................................................................................824 PEDAL CONTROLS............................................................................................................................826 Throttle Pedal........................................................................................................................826 Service Brake Pedal...................................................................................................................826 Optional Dual Function/ Single Pedal..................................................................................................826 Dynamic Retarding Pedal...............................................................................................................826 OVERHEAD CONTROLS, GAUGES, ETC............................................................................................................827 Grade/speed Warning Chart.............................................................................................................827 Radio Speakers........................................................................................................................827 Warning Alarm Buzzer..................................................................................................................827 Cab Radio.............................................................................................................................827 Warning Lights Dimmer Control.........................................................................................................827 Status / Warning Indicator Light Panel................................................................................................827 Windshield Wipers.....................................................................................................................827 Air Cleaner Vacuum Gauges.............................................................................................................828 CENTER CONSOLE CONTROLS...................................................................................................................828 F-N-R Selector Switch.................................................................................................................828 Hoist Control.........................................................................................................................829 Ash Tray..............................................................................................................................829 Lighter...............................................................................................................................829 Window Switches.......................................................................................................................829 Engine Shutdown Switch................................................................................................................829 Override Switch.......................................................................................................................830 Retard Speed Control (RSC) Switch.....................................................................................................830 RSC Adjust Dial.......................................................................................................................830 Operation.............................................................................................................................830 RSC Control Adjustment................................................................................................................831 Statex III Propulsion System Diagnostic Connector.....................................................................................831 Modular Mining Port Conector..........................................................................................................831 Unused Connector......................................................................................................................831 Komatsu Engine Quantum Connector......................................................................................................831 Komatsu Engine Cense Connector........................................................................................................831 Data Store Button.....................................................................................................................831 Passenger Seat........................................................................................................................831 Service Engine Light (Blue)...........................................................................................................831 Payload Meter (Not Shown).............................................................................................................831 INSTRUMENT PANEL AND INDICATOR LIGHTS.....................................................................................................832 CONTROL SYMBOLS.......................................................................................................................832 INSTRUMENT PANEL..........................................................................................................................833 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-7).......................................................................................834 Key Switch............................................................................................................................834 Engine Shutdown Switch (with Timer Delay).............................................................................................834 Operation.............................................................................................................................834 To Cancel Delay Sequence..............................................................................................................834 Fog Lights (Optional).................................................................................................................834 Ladder Light Switch...................................................................................................................834 Backup Light Switch...................................................................................................................834 Panel Illumination Lights.............................................................................................................835 Cab Air Conditioner/heater Vents......................................................................................................835 Engine Cold Weather Starting Aid (Optional)...........................................................................................835 Operation.............................................................................................................................835 Rotating Beacon Light Switch (Optional)...............................................................................................835 Heated Mirror Switch (Optional).......................................................................................................835 Blank (Not Used In This Application)..................................................................................................835 Wheel Brake Lock Control..............................................................................................................835 Operation.............................................................................................................................835 Parking Brake Control.................................................................................................................836 Tachometer............................................................................................................................836 Right Turn Signal Indicator...........................................................................................................836 High Beam Indicator...................................................................................................................836 Left Turn Signal Indicator............................................................................................................836 Speedometer / Payload Meter...........................................................................................................836 Voltmeter.............................................................................................................................836 Engine Oil Pressure Gauge.............................................................................................................836 Water Temperature Gauge...............................................................................................................837 Fuel Gauge............................................................................................................................837 Blank.................................................................................................................................837 Hourmeter.............................................................................................................................837 The hourmeter (24, Figure 5- 7) registers the total number of hours the truck engine has been operating...............................837 Blank.................................................................................................................................837 Headlight Switch......................................................................................................................837 Panel Light Dimmer....................................................................................................................837 Payload Meter Switch..................................................................................................................837 OVERHEAD STATUS / WARNING INDICATOR LIGHTS................................................................................................838 INDICATOR LIGHTS......................................................................................................................839 LUBRICATION AND SERVICE...........................................................................................................................845 LUBRICATION AND SERVICE.......................................................................................................................847 Service Capacities........................................................................................................................847 HYDRAULIC TANK SERVICE....................................................................................................................847 Adding Oil............................................................................................................................847 COOLANT LEVEL CHECK.......................................................................................................................848 Radiator Filling Procedure............................................................................................................848 Anti-Freeze Specifications............................................................................................................848 RESERVE ENGINE OIL SYSTEM (Optional)......................................................................................................848 Reserve Oil Tank Filling Procedure (Remote fill)......................................................................................848 10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS........................................................................................850 10 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................................................................850 LED Light Signals:................................................................................................................850 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................................852 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................853 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................854 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (CONTINUED)...................................................................................855 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................856 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................................................................................857 2500 HOUR MAINTENANCE CHECKS..............................................................................................................858 5000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................................................................................859 10,000 HOURS LUBRICATION AND MAINTENANCE CHECKS...........................................................................................859 AUTOMATIC LUBRICATION SYSTEM..................................................................................................................861 GENERAL DESCRIPTION.......................................................................................................................861 SYSTEM COMPONENTS.........................................................................................................................863 System Operation..........................................................................................................................864 Normal Operation......................................................................................................................864 Pressure Failure Detection Circuits...................................................................................................865 INJECTOR OPERATION........................................................................................................................866 STAGE 1...............................................................................................................................866 STAGE 2...............................................................................................................................866 STAGE 3...............................................................................................................................866 STAGE 4...............................................................................................................................866 GENERAL INSTRUCTIONS......................................................................................................................867 LUBRICANT REQUIRED FOR SYSTEM.........................................................................................................867 SYSTEM PRIMING........................................................................................................................867 FILTER ASSEMBLY.......................................................................................................................867 LUBRICANT PUMP........................................................................................................................868 Pump Housing Oil Level................................................................................................................868 Pump Pressure Control.................................................................................................................868 Pressure Control Valve Adjustment.....................................................................................................868 INJECTORS (SL-1 Series "H")...........................................................................................................869 Injector Specifications...............................................................................................................869 Injector Adjustment...................................................................................................................869 SYSTEM CHECKOUT.......................................................................................................................870 24 VDC TIMER CHECK................................................................................................................870 Lubrication Cycle Timer Adjustment................................................................................................870 PUMP REBUILD......................................................................................................................871 Disassembly.......................................................................................................................871 Cleaning and Inspection...........................................................................................................871 Assembly..........................................................................................................................873 SYSTEM TROUBLESHOOTING CHART..............................................................................................................874 Preventative Maintenance Procedures.......................................................................................................877 Daily Lubrication System Inspection...................................................................................................877 250 Hour Inspection...................................................................................................................877 1000 Hour Inspection..................................................................................................................877 MOTORIZED WHEEL MAINTENANCE SCHEDULE..........................................................................................................879 ALPHABETICAL INDEX................................................................................................................................883 SYSTEM SCHEMATICS.................................................................................................................................887 EG4934 BRAKE SCHEMATIC........................................................................................................................889 EK4841 HYDRAULIC SCHEMATIC....................................................................................................................890 HE481 PAYLOAD METER III SCHEMATIC.............................................................................................................891 XS2100 ELECTRIC SCHEMATIC.....................................................................................................................892 XS2101 INDEX & SYMBOLS....................................................................................................................892 XS2102 CIRCUIT NUMBER LOCATOR.............................................................................................................893 XS2103 COMPONENT LOCATOR..................................................................................................................894 XS2104 COMPONENT LOCATOR..................................................................................................................895 XS2105 POWER DISTRIBUTION - 24VDC.........................................................................................................896 XS2106 PWR 18 ELEM., 3 STEP RETARDING.....................................................................................................897 XS2107 PWR 18 ELEM., 7 STEP RETARDING.....................................................................................................898 XS2108 PWR 20 ELEM., 7 STEP RETARDING.....................................................................................................899 XS2109 DRIVE SYSTEM CONTROL CIRCUITS......................................................................................................900 XS2110 TWO DIGIT DISPLAY..................................................................................................................901 XS2111 G.E. DIG. INPUTS, LUBE CENTER TEST.................................................................................................902 XS2112 REAR TAIL LTS, DIMMER CONTROL......................................................................................................903 XS2113 5 MINUTE IDLE, SPARE WIRES.........................................................................................................904 XS2114 WINDOWS, RADIO, GAUGES.............................................................................................................905 XS2115 CONTACTOR FEEDBACK.................................................................................................................906 XS2116 CONTACTOR COILS....................................................................................................................907 XS2117 MACHINE CONTROL CIRCUITS...........................................................................................................908 XS2118 ACCELERATOR, RETARD PEDALS.........................................................................................................909 XS2119 HYDRAULIC CONTROLS, ALARMS.........................................................................................................910 XS2120 HTR/AC, WINDSHIELD WIPER CONTROLS..................................................................................................911 XS2121 LIGHT CONTROL CIRCUITS.............................................................................................................912 XS2122 INSTR. LIGHTS, DIAGNOSTIC PORTS....................................................................................................913 XS2123 MODULAR MINING DISPATCH............................................................................................................914 XS2124 CUMMINS QSK-60 ENGINE..............................................................................................................915 XS2125 CUMMINS QSK-60 ENGINE..............................................................................................................916 XS2126 ELECTRONIC HOIST CONTROLLER........................................................................................................917 EL0114 VHMS SCHEMATIC.........................................................................................................................918
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