Komatsu 630E Dump Truck Shop Manual DG675 – PDF DOWNLOAD

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Komatsu 630E Dump Truck Shop Manual DG675 – PDF DOWNLOAD

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Komatsu 630E Dump Truck Shop Manual DG675 – PDF DOWNLOAD

Language : English
Pages :885
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 630E Dump Truck Shop Manual DG675 – PDF DOWNLOAD

SERIAL SUFFIX
AFE42-M
and up AFE46-U

FOREWORD

This Service 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 HAULPAK® Model designation consists of three numbers and one letter (i.e. 630E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and 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 630E Dump Truck Shop Manual DG675 – PDF DOWNLOAD

SERIAL SUFFIX
AFE42-M
and up AFE46-U

MAIN MENU 0
COVER 1
FOREWORD 7
TABLE OF CONTENTS 9
SECTION A GENERAL INFORMATION INDEX 11
MAJOR COMPONENT DESCRIPTION 13
ENGINE 13
ALTERNATOR 13
WHEEL MOTORS (GE 776) 13
BLOWER 13
OPERATOR’S CAB 13
POWER STEERING 13
DYNAMIC RETARDING 13
BRAKE SYSTEM 13
SUSPENSION 13
GENERAL SAFETY AND OPERATION 17
SPECIFICATIONS 15
ENGINES (Standard Options) 15
Cummins KTTA 50-C 15
Detroit Diesel 16V-149TIB 15
ELECTRIC DRIVE SYSTEM 15
STATEX III AC/DC Current 15
DYNAMIC RETARDING 15
BATTERY ELECTRIC SYSTEM 15
SERVICE CAPACITIES 15
AIR SYSTEM 15
HYDRAULIC SYSTEM 15
SERVICE BRAKES 16
STEERING 16
DUMP BODY 16
TIRES 16
WEIGHT DISTRIBUTION 16
EMPTY 16
LOADED 16
OVERALL TRUCK DIMENSIONS 16
SAFETY IS THINKING AHEAD 17
Safe practices start before the operator gets to the equipment! 17
PREPARING FOR OPERATION 17
ENGINE START-UP SAFETY PRACTICES 18
AFTER ENGINE HAS STARTED 19
SAFETY PRECAUTIONS DURING TRUCK OPERATION 19
LOADING 20
HAULING 21
PASSING 21
DUMPING 21
To Raise dump body: 22
To Lower Body: 22
TOWING 22
WHEN REPAIRS ARE NECESSARY 23
SAFE PARKING PROCEDURES 24
SHUTDOWN PROCEDURE 24
WARNINGS AND CAUTIONS 25
STANDARD CHARTS AND TABLES 31
STORAGE PROCEDURES 37
SECTION B STRUCTURES INDEX 57
STRUCTURAL COMPONENTS 59
GRILLE AND HOOD 59
Removal 59
Installation 59
DECKS 59
Removal 60
Installation 62
DUMP BODY 65
DUMP BODY 65
Removal 65
Installation 66
BODY PAD 66
Body Pad Adjustment 67
BODY GUIDE 67
BODY POSITION INDICATOR 67
BODY SLING 67
Body Sling Hook-Up 67
ROCK EJECTORS 68
Inspection 68
BODY-UP LIMIT SWITCH 69
Indicator Arm Adjustment 69
FUEL TANK 71
FUEL TANK 71
Removal 71
Installation 72
Cleaning 72
BREATHER 72
GAUGE 72
Removal 72
Installation 72
SECTION C ENGINE INDEX 73
POWER MODULE 75
POWER MODULE 75
Removal 75
Installation 79
COOLING SYSTEM 81
RADIATOR 81
Removal 81
Service 81
Installation 81
Visual Inspection 82
Pressure Cap 82
Water Temperature Thermostats 82
POWER TRAIN 83
ALTERNATOR 83
Removal 83
Installation 84
ENGINE/ALTERNATOR MATING 84
Alternator End Play Measurement 84
Engine Endplay Measurement 85
Determining Shim Requirements 86
Installing Alternator on Engine 86
ENGINE 87
Removal 87
Service 88
Installation 88
FAN 88
AIR CLEANERS 91
FILTER ELEMENT REPLACEMENT 91
MAIN FILTER ELEMENT CLEANING 93
PRECLEANER SECTION 94
ENGINE COMPONENTS 97
THROTTLE CONTROL AIR CYLINDERS 97
Detroit Diesel Engine 97
Removal 97
Installation 97
Adjustment 98
Cummins Engine 98
Removal 98
Installation 98
Adjustment 99
LOW IDLE SOLENOID 99
Service 99
THROTTLE SOLENOID 99
Service 99
Operating Test 99
SECTION D ELECTRICAL SYSTEM INDEX101
24 VDC ELECTRIC SUPPLY SYSTEM103
ELECTRICAL SYSTEM DESCRIPTION103
BATTERY103
Maintenance and Service103
Troubleshooting103
BATTERY CHARGING SYSTEM105
General Description105
Operating Principles105
Energizing Speed105
Rated Voltage106
Magnetizing The Rotor106
INTEGRAL CHARGING SYSTEM (Battery Charging Alternator)107
Troubleshooting Procedures107
Integral Charging System Repair107
Regulator Check108
Rectifier Bridge Check (Omit for Overcharged Battery)108
Field Coil Checks108
Diode Trio Check108
Stator Checks (Omit for Overcharged Battery)109
Disassembly (Refer to Figure 2-10)109
Reassembly110
24 VDC ELECTRICAL SYSTEM COMPONENTS113
ALARM INDICATING DEVICE (AID) SYSTEM113
BODY-UP SWITCH115
Adjustment115
Service115
HOIST LIMIT SWITCH115
Adjustment115
Service115
GROUND LEVEL SHUTDOWN116
For Detroit Diesel (Without DDEC)116
For Detroit Diesel (With DDEC II or DDEC III)116
For Cummins Engines (With air throttle)116
For Cummins Engines (With Centry throttle control)116
24 VOLT RELAY BOARDS117
Description118
Service118
RELAY BOARD DESCRIPTIONS120
Relay Board 1 Turn Signal120
Relay Board 2 Payload Meter (Optional)120
Relay Board 3 Stop Lights120
Relay Board 4 Parking Brake120
Relay Board 5 Head Lights121
Relay Board 6 Auxiliary Panel121
DIODE BOARDS122
Diode Board 1122
Diode Board 2123
CIRCUIT BREAKERS124
SECTION E ELECTRICAL PROPULSION COMPONENTS INDEX125
ELECTRICAL PROPULSION COMPONENTS127
GENERAL SYSTEM DESCRIPTION127
CONTROL SYSTEM127
System Operation128
17FL275 PANEL129
COMPUTER DESCRIPTION131
SOFTWARE131
CARD REPLACEMENT130
Removal130
Installation130
Card Repair130
COMPUTER DESCRIPTION131
Microprocessor131
Download Capability131
SOFTWARE131
Base Monitor Program131
Runtime Monitor Program – OBJ Running Code131
Configuration Software – CFG132
PTU – Portable Test Unit Code132
System Regulation132
Propulsion132
Retarding133
2-DIGIT DISPLAY PANEL134
The Coded Number134
Events134
Frames135
Windows135
System Categories135
Limits On Resetting Faults135
Na Faults136
Event Sequence136
Resetting Events136
Event Descriptions136
Subcode Descriptions136
2-DIGIT DISPLAY PANEL CODES137
PORTABLE TEST UNIT (PTU)146
DESCRIPTION146
OPERATIONAL HINTS146
SOFTWARE INSTALLATION PREPARATION147
Deleting Prior Software Versions147
Computer Boot File Editing147
SOFTWARE INSTALLATION ON PTU148
THE MAIN MENU149
PTU SOFTWARE MENU TREE150
CONFIGURATION (CFG) FILE CONVERSION151
Conversion Procedure151
STATEX CONFIGURATION FILES157
“Change Ptu Password”167
PROGRAMMING THE TRUCK168
Connect PTU to the Truck168
Select Configuration File168
Activate The PTU Mode168
Check Object Code Version169
Download Configuration Files170
Date And Time171
Event Data172
STATISTICAL DATA174
“View Counters”174
“View Profiles”174
“Upload Statistical Data To A File”174
Statistical Data Codes – Counters175
STATISTICAL DATA CODES – PROFILES181
Truck Specific Information185
Temporary Truck Settings186
MISCELLANEOUS FEATURES187
Saving Data187
Ptu Abbreviations187
OTHER MENU SELECTIONS187
PANEL WIRING130
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS189
ALTERNATOR189
ELECTRIC WHEEL MOTORS189
RETARDING GRIDS189
AIR THROTTLE/ELECTRONIC RETARD CONTROL190
Acceleration Switch [AS]190
Range Adjustment190
Differential Adjustment190
Removal190
Installation190
Disassembly and Assembly191
Adjustment Procedure (On Bench)191
Adjustment Procedure (On Truck)191
PROPEL/RETARD INTERFACE PANELS (Non-Fuel Saver Only)191
ACC Panel Operation191
RET Panel Operation191
ELECTRONIC ACCELERATOR AND RETARD PEDALS192
Removal192
Installation192
Disassembly192
Assembly192
COOLING BLOWER WARNING SYSTEM193
Operation193
Test193
Removal193
Installation193
ELECTRICAL CONTROL CABINET194
ABBREVIATION FOR STATEX III ELECTRIC DRIVE COMPONENTS200
DETROIT DIESEL ELECTRONIC ENGINE CONTROLS ABBREBIATIONS201
CARD IDENTIFICATION LIST GE17FL275 PANEL, STATEX III201
CHECKOUT PROCEDURE STATEX III ELECTRICAL SYSTEM203
GENERAL INFORMATION205
COMMUNICATIONS PORT CHECK206
PTU Hookup206
10 SEQUENCE TESTS – (Engine not running)208
11 Throttle System Check and Adjustment209
111 Electronic Throttle System (Williams electronic foot pedal, Dresser ACC/RET Interface Circuit and Pedal Detector Card)209
112 Electronic Throttle System (Fuel Saver System)210
12 Retard System Check and Adjustment212
121 Williams Electronic Retard Pedal and Dresser ACC/RET or RET Interface Box212
122 Electronic Retard Pedal; Fuel Saver Equipped Trucks and Current Production213
13 Reverser and Propulsion Contactors Check215
14 Propulsion Lockout Test (DDEC & MTU Engine Trucks Only)216
15 Retard Contactors Operation Check217
16 Ground Fault Sensing Check217
17 Ground Fault in Retard Operation Check217
18 Override Operation Check218
19 Anti-Reversal Function (AR) Check219
110 Overspeed Retard Operation Check219
111 Hoist Interlock Operation Check220
112 Motor Blower Fault Light Operation Check221
20 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL222
21 Setup Manual Digital Input/Output Test on PTU222
22 Digital Input Checks223
23 Digital Output Checks225
30 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL228
31 Setup Analog Input Monitor Screen on PTU228
32 Analog Input Checks229
33 Frequency Input Checks236
40 SPEED EVENT CHECKS238
41 Single Speed Overspeed Truck – Overspeed Settings Check239
42 Two Speed Overspeed Truck (Empty Truck) – Overspeed Settings Check239
43 Two Speed Overspeed Truck (Loaded Truck) – Overspeed Settings Check239
44 Other Speed Events Checks239
50 RETARD SPEED CONTROL SYSTEM CHECK241
51 Overspeed Pickup and Dropout Check241
52 Retard Pot Maximum Setting Check242
53 Retard Pot Minimum Setting Check242
54 Accelerator Pedal Override of Retard Speed Control242
60 LOAD TEST USING TRUCK RETARD GRIDS243
61 Load Test244
70 MOTOR FIELD CURRENT CHECK IN RETARDING245
71 Retard Check245
80 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT246
81 Brake System Interlocks Check246
82 Blower Loss Pressure Switch Adjustment247
83 SYNC Transformer Checkout247
84 Power Contactor Position Sensor Adjustment247
85 Battery Boost Adjustment248
86 Isolation amplifier & voltage module test248
861 Voltage Measuring Module Test (VMM1 and VMM2)248
862 ISOA3, ISOA4, ISOA5, ISOA6, ISOA-7, and ISOA-8 Test249
87 Motor Rotation Test249
88 Ground Fault Checks250
90 MISCELLANEOUS CHARTS251
91 Wheel Motor Gear Ratios251
92 Maximum Allowable Truck Speeds252
93 Engine Options253
SECTION G REAR AXLE SPINDLES AND WHEELS INDEX255
TIRES AND RIMS257
FRONT TIRES AND RIMS258
Removal258
Installation258
REAR TIRE AND RIM259
Removal259
Installation260
RIM260
Tire Removal260
Tire Installation261
FRONT WHEEL HUB AND SPINDLE263
FRONT WHEEL HUB263
Removal263
Installation264
Disassembly265
Cleaning and Inspection266
Assembly266
Wheel Bearing Adjustment268
Field Adjustment268
STEERING CYLINDERS AND TIE ROD270
Removal270
Installation271
Bearing Replacement271
TOE-IN ADJUSTMENT272
(Bias Ply Tires)272
(Radial Tires)272
REAR AXLE HOUSING ATTACHMENT273
HITCH PIN273
Removal273
Installation273
PIVOT PIN BEARING274
Disassembly274
Assembly274
PIVOT EYE REPAIR275
Removal275
Installation275
ANTI-SWAY BAR276
Removal276
Installation276
Disassembly276
Cleaning and Inspection276
Assembly276
REAR AXLE HOUSING277
REAR AXLE HOUSING277
WHEEL MOTOR277
REAR AXLE HOUSING BUMPER PAD278
SECTION H HYDRAIR II SUSPENSIONS INDEX279
FRONT SUSPENSION281
FRONT SUSPENSION281
Removal281
Installation282
Disassembly285
Cleaning and Inspection285
Assembly286
REAR SUSPENSION289
REAR SUSPENSION289
Removal289
Installation290
Disassembly290
Cleaning and Inspection292
Assembly292
OILING AND CHARGING PROCEDURES295
GENERAL295
EQUIPMENT LIST295
HYDRAIR® CHARGING KIT295
Installation of Charging Kit295
Removal of Charging Kit296
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS296
FRONT SUSPENSION297
Front Suspension Oiling297
Front Suspension Nitrogen Charging298
REAR SUSPENSION299
Rear Suspension Oiling299
Rear Suspension Nitrogen Charging300
SECTION J BRAKE CIRCUIT INDEX303
BRAKE CIRCUIT305
Operation305
BRAKE CIRCUIT COMPONENT DESCRIPTION305
Normal Brake Application305
Slippery Road Operation307
Wheel Brake Lock Operation307
Secondary Brake Switch Operation307
Automatic Emergency Brake Application307
Parking Brake307
BRAKE CIRCUIT COMPONENT SERVICE309
DUAL CONTROLLER309
Operation Of Brake Controller Components309
Removal310
Installation310
Service315
Disassembly315
Cleaning and Inspection316
Assembly317
BENCH ADJUSTMENT318
Equipment Required:318
Adjustments319
HYDRAULIC BRAKE CONTROLLER TROUBLESHOOTING321
HYDRAULIC BRAKE ACCUMULATORS325
Brake Accumulator Bleed Down Procedure325
Removal325
Installation325
Disassembly325
Cleaning and Inspection326
Assembly327
Charging Procedure328
DIFFERENTIAL PRESSURE MANIFOLD329
Removal329
Installation329
Disassembly329
Cleaning and Inspection330
Assembly and Initial Adjustment330
Final Adjustment331
PILOTED SINGLE CONTROLLER331
Removal331
Installation332
Disassembly332
Cleaning and Inspection332
Assembly332
Bench Test332
Equipment Needed:333
Set-Up333
Adjustment333
DRY/SLIPPERY ROAD SOLENOID VALVE334
Removal334
Installation334
Disassembly335
Cleaning and Inspection335
Assembly335
BRAKE CIRCUIT CHECK OUT AND ADJUSTMENT PROCEDURE337
BRAKE CIRCUIT COMPONENT LEAKAGE TEST337
Accumulators337
Dual Controller and Piloted Single Controller338
Dry/Slippery Road Valve338
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT339
FRONT WHEEL SPEED DISC BRAKES343
CARLISLE WHEEL SPEED DISC BRAKES343
BRAKE CALIPERS343
Lining Replacement343
Brake Caliper Removal344
Brake Caliper Installation345
Brake Caliper Disassembly345
Inspection345
Brake Caliper Assembly346
BRAKE CALIPER BENCH TEST347
BRAKE BLEEDING PROCEDURE347
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE348
Front Brake Conditioning348
Temporary Disconnect Procedures For Rear Brakes348
Temporary Disconnect Procedures for Disabling Rear Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks349
Temporary Disconnect Procedures for Disabling Rear Brakes For Model 830E HAULPAK® Trucks349
SPECIAL TOOLS350
ROCKWELL WHEEL SPEED FRONT DISC BRAKES351
BRAKE CALIPER351
BRAKE LINING355
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE355
TEMPORARY DISCONNECT PROCEDURES FOR REAR BRAKES356
BRAKE BLEEDING PROCEDURES358
REAR ARMATURE SPEED DISC BRAKES359
CARLISLE ARMATURE SPEED REAR DISC BRAKES359
BRAKE CALIPERS359
Lining Replacement359
Caliper Removal360
Inspection362
Installation363
Disassembly of Brake Calipers364
Inspection366
Caliper Assembly366
BRAKE CALIPER BENCH TEST367
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE368
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE368
General368
Carlisle Armature Speed Disc Brakes Conditioning (Burnishing) Rear Brakes368
BLEEDING PROCEDURE369
TEMPORARY DISCONNECT PROCEDURES FOR DISABLING FRONT BRAKES369
Temporary Disconnect Procedures for Disabling Front Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks370
Temporary Disconnect Procedures for Disabling Front Brakes For Model 830E HAULPAK® Trucks370
ROCKWELL ARMATURE SPEED REAR DISC BRAKES371
REAR BRAKES371
CALIPER, DISC AND PARKING BRAKE371
FUNCTIONAL TEST OF PISTON ASSEMBLY377
BRAKE LINING383
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE385
BLEEDING PROCEDURE386
REAR DISC PARKING BRAKE397
CARLISLE DISC PARKING BRAKE397
PARKING BRAKE OPERATION397
TRUCKS WITH ROCKWELL SERVICE BRAKES397
Caliper Removal397
Caliper Installation398
TRUCKS WITH CARLISLE SERVICE BRAKES399
Caliper Removal399
Caliper Installation399
Lining Replacement400
Caliper Disassembly400
Inspection400
Caliper Assembly401
BRAKE CALIPER BENCH TEST402
PARKING BRAKE BLEEDING402
CONDITIONING PROCEDURE FOR DISC PARKING BRAKE402
500 HOUR SERVICE GUIDE FOR DISC PARKING BRAKE403
ROCKWELL DISC PARKING BRAKE405
CALIPER STYLE IDENTIFICATION405
REMOVAL406
INSTALLATION406
PARKING BRAKE ADJUSTMENT (SCL 70)406
PARKING BRAKE ADJUSTMENT (SCL15)408
PARK BRAKE CALIPER DISASSEMBLY409
CLEANING AND INSPECTION410
PARK BRAKE CALIPER ASSEMBLY411
PARK BRAKE LINING REPLACEMENT411
PARK BRAKE BURNISH PROCEDURE411
BRAKE BLEEDING PROCEDURE411
SECTION K AIR SYSTEM INDEX413
AIR SYSTEM OPERATION415
AIR COMPONENT DESCRIPTION416
Air Compressor416
Air Starter Circuit (If Equipped*)416
Air Dryer/Aftercooler416
Air Dryer (If Equipped)416
Aftercooler (If Equipped)416
Check Valve417
Main Air Tank417
Safety Valve417
Automatic/Manual Drain Valve417
Air Governor418
Radiator Pressure Regulating Valve (Detroit Diesel Engine Only)418
90 psi (622 kPa) Air Regulating Valve For Contact Relays418
Air System Lubricator (If Equipped)419
Shop Air Quick Disconnect419
AIR SYSTEM COMPONENT REPAIR421
AIR COMPRESSOR SERVICE421
AIR DRYER/AFTERCOOLER421
SAFETY VALVE421
Operating Test421
AIR GOVERNOR421
Disassembly421
Cleaning and Inspection422
Assembly422
Adjustment422
Leakage Tests422
AUTOMATIC/MANUAL DRAIN VALVE423
Removal423
Installation423
Disassembly423
Cleaning and Inspection423
Assembly424
RADIATOR PRESSURE REGULATING VALVE (Detroit Diesel Engine Only)424
Removal424
Installation and Adjustment424
Disassembly424
Cleaning and Inspection425
Assembly425
AIR PRESSURE REGULATING VALVE FOR CONTACT RELAYS [90 psi (622 kPa)]425
Removal425
Installation425
Disassembly425
Cleaning and Inspection425
Assembly426
Adjustment426
AIR STARTER CIRCUIT (If Equipped)426
AIR SYSTEM LUBRICATOR (If Equipped)426
Service426
Adjustment426
AIR STARTER CIRCUIT427
DUMP VALVE428
AIR START SOLENOID VALVE428
AIR STARTER428
AIR STARTER COMPONENT REPAIR429
AIR START SOLENOID VALVE429
Removal429
Installation429
Disassembly429
Cleaning and Inspection429
Service429
Assembly429
DUMP VALVE429
Removal429
Installation430
AIR STARTER430
Removal430
Installation430
Disassembly Tips430
Disassembly430
Assembly433
Test and Inspection Procedure436
AIR STARTER LUBRICATOR430
Removal430
Installation430
TROUBLESHOOTING CHART437
THROTTLE TREADLE VALVE439
COMPONENT DESCRIPTION439
Treadle Valve439
Service439
COMPONENT REPAIR439
Removal439
Installation439
Disassembly439
Inspection440
Assembly441
SECTION L HYDRAULIC SYSTEM INDEX443
HYDRAULIC SYSTEM445
HYDRAULIC SYSTEM OPERATION445
COMPONENT DESCRIPTION445
High Pressure Filters445
Hydraulic Pump445
Hydraulic Tank446
HYDRAULIC SYSTEM (With Trolley Assisted Option)447
HYDRAULIC SYSTEM DESCRIPTION447
HYDRAULIC SYSTEM COMPONENT REPAIR449
HYDRAULIC PUMP449
Removal449
Installation450
Pump Disassembly450
Pump Assembly451
Cartridge Disassembly452
Inspection454
Cartridge Assembly455
TROUBLESHOOTING CHART457
HYDRAULIC TANK458
Filling Instructions458
Removal459
Installation459
HYDRAULIC TANK STRAINER AND DIFFUSER459
Removal459
Inspect and Clean460
Installation460
HYDRAULIC SYSTEM FLUSHING PROCEDURE461
STEERING CIRCUIT463
STEERING CIRCUIT OPERATION463
COMPONENT DESCRIPTION463
Steering Control Valve463
Unloader Valve463
Operation464
Bleeddown Manifold466
Bleeddown Solenoid466
Accumulators466
High Pressure Filter466
Flow Amplifier466
FLOW AMPLIFIER SYSTEM OPERATION468
No Steer468
Steering Left470
Steering Right472
No Steer, External Shock Load474
STEERING CONTROL VALVE477
STEERING CONTROL VALVE477
Removal477
Installation477
Disassembly478
Cleaning and Inspection479
Assembly481
Alternate Method for Installing Centering Springs481
STEERING CIRCUIT COMPONENT REPAIR485
UNLOADER VALVE485
Removal485
Installation and Adjustment485
REBUILDING UNLOADER VALVE485
Disassembly485
Clean and Inspect486
Assembly486
BLEEDDOWN MANIFOLD487
Removal487
Adjusting Relief Valve487
Testing and Adjustment488
FLOW AMPLIFIER489
Removal489
Installation489
Disassembly489
Assembly492
ACCUMULATORS493
Removal493
Installation493
Cleaning and Inspection494
Assembly494
STEERING ACCUMULATOR CHARGING PROCEDURE495
STEERING CYLINDERS496
Disassembly496
Assembly496
STEERING CIRCUIT FILTER (OPTIONAL)498
Removal498
Installation498
STEERING CIRCUIT TEST PROCEDURE499
PRESSURE ADJUSTMENT PROCEDURE499
COMPONENT LEAKAGE TEST501
TROUBLESHOOTING CHART502
HOIST CIRCUIT505
HOIST CIRCUIT OPERATION505
COMPONENT DESCRIPTION506
Hydraulic Tank506
Hydraulic Pump506
High Pressure Filters506
Hoist Valve506
Hoist Pilot Valve507
Hoist-up Limit Solenoid508
Pilot Operated Check Valve508
Hoist Valve Operation508
Float Operation508
Power Up Operation (Figure 7-4)510
Hold Operation (Figure 7-5)512
Power Down Operation (Figure 7-6)514
Float Operation (Figure 7-7)516
HOIST CIRCUIT COMPONENT REPAIR519
HOIST VALVE519
Removal519
Installation520
Disassembly520
INLET SECTION521
Disassembly521
Cleaning and Inspection522
Reassembly522
SPOOL SECTION522
Disassembly522
Cleaning and Inspection524
Reassembly524
HOIST PILOT VALVE525
Removal525
Installation525
Disassembly525
Cleaning and Inspection526
Reassembly526
HOIST CYLINDERS527
Removal527
Installation528
Disassembly528
Cleaning and Inspection530
ASSEMBLY OF QUILL AND CYLINDER531
Quill Installation531
Installation Of Check Balls And Plugs In Quill532
Assembly of Cylinder533
HIGH PRESSURE FILTERS534
Removal534
Installation534
BODY UP LIMIT SOLENOID535
PILOT OPERATED CHECK VALVE535
CHECKING HOIST SYSTEM PRESSURE RELIEF VALVE535
SECTION M OPTIONS AND SPECIAL TOOLS INDEX537
FIRE CONTROL SYSTEM (M02002)541
FIRE CONTROL SYSTEM (MANUAL) (02004)557
ANSUL AUTOMATIC FIRE CONTROL SYSTEM (CHECKFIRE PNEUMATIC) (02002)541
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 (02003)547
LINCOLN AUTOMATIC LUBRICATION SYSTEM (M03001)559
OPERATION559
Operation559
Components559
Description of Components559
GENERAL INSTRUCTIONS560
Lubricant Required for System560
Initial Reservoir Fill560
System Priming560
SYSTEM CHECKOUT561
24 VDC SOLID STATE TIMER CHECK561
INJECTORS (SL-1 SERIES “H”)562
TROUBLESHOOTING CHART564
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM (M04002)567
SYSTEM ADJUSTMENT567
PUMP567
BLOWER DRIVE MOTOR570
BLOWER BEARING REPAIR573
AIR CLEANER574
WIGGINS QUICK FILL FUEL SYSTEM (M05002)575
TANK BREATHER VALVE576
FUEL RECEIVER575
FAN DRIVE CLUTCH (M06001)579
GENERAL DESCRIPTION579
MAINENANCE582
TROUBLESHOOTING584
FIELD CHECK DIAGNOSIS585
THERMAL SENSOR AND SOLENOID VALVE586
TROUBLESHOOTING CHART589
COMPONENTS PARTS LIST592
DISASSEMBLY INSTRUCTIONS593
REASSEMBLY OF THE FAN CLUTCH600
INSPECTION OF PARTS611
REBUILD TOOLS616
ENGINE COOLANT HEATER (M07001)617
HEATING ELEMENT617
THERMOSTAT618
ENGINE OIL HEATERS (M07003)619
TROUBLESHOOTING619
HEATING ELEMENT619
ENGINE COOLANT & OIL HEATERS, 440 VOLT (M07004)621
TROUBLESHOOTING622
COOLANT HEATER ELEMENT623
OIL HEATER ELEMENT624
THERMOSTAT625
SPECIAL TOOLS (M08008)627
AIR CONDITIONING SYSTEM (M09003)633
PRINCIPLES OF REFRIGERATION634
Refrigeration – The Act Of Cooling634
The Refrigeration Cycle635
AIR CONDITIONER SYSTEM COMPONENTS635
Compressor (Refrigerant Pump)635
Service Valves635
Condenser635
Filter Receiver-drier636
Fusible Pressure Relief Plug636
Thermostatic Expansion Valve636
Evaporator636
Superheat637
SYSTEM SERVICING639
R-12 Containers639
TROUBLESHOOTING656
PRE-DIAGNOSIS CHECKS656
PREPARING FOR DIAGNOSIS656
PRELIMINARY STEPS656
DIAGNOSIS OF GAUGE READINGS & SYSTEM PERFORMANCE656
TROUBLESHOOTING CHART657
HEATER/AIR CONDITIONER SERVICE661
COMPONENT SERVICE661
Refrigerant Discharge661
COMPRESSOR662
Cylinder Head (Gasket) Removal662
Installation662
Compressor Removal662
Installation662
CONDENSER662
Removal663
Installation663
RECEIVER/DRYER663
Removal663
Installation663
EVAPORATOR COIL, THERMOSTAT SWITCH, AND EXPANSION VALVE663
EXPANSION VALVE664
Removal664
Installation665
BLOWER MOTOR ASSEMBLY665
Removal666
Installation667
Blower Disassembly667
Blower Assembly667
AFTERCOOLER OPERATION AND REPAIR669
OPERATION669
MAINTENANCE669
Removal669
Installation669
Disassembly670
Cleaning and Inspection671
Assembly671
AIR DRYER (AEROFINER III) (M10003)673
AIR DRYER673
Service673
Indications To Change Desiccant673
Removal674
Installation674
Disassembly674
Assembly675
CHECK VALVE675
Removal675
Installation675
PURGE VALVE & HEATER676
Removal676
Inspection676
Installation676
SALEM AFTERCOOLER (AIR DRYER) (M10004)677
AFTERCOOLER/AIR DRYER677
Removal677
Disassembly677
Cleaning and Inspection677
Reassembly and Installation677
OPTIONAL OPERATOR SEAT (M14001)679
SEAT679
Removal679
Installation679
Disassembly680
Assembly682
Air Suspension Cam Adjustment683
SEAT MAINTENANCE AND REPAIR684
Headrest684
Backrest684
Armrests684
Seat Cushion684
Seat Frame684
Slides685
Suspension685
TDI SINGLE STAGE AIR STARTER (M15001)689
Disassebly689
PARTS INSPECTION (Refer to Figure 15-2 for reference to parts)694
Assembly696
TDI TWO-STAGE AIR STARTER703
AIR STARTER703
Removal703
Installation703
Description of Basic Groups703
Disassembly706
Cleaning and Inspection708
Assembly710
STARTER689
Removal689
Installation689
Disassembly689
Cleaning693
Parts Inspection693
AUTOMATIC TRIP VALVE700
Disassembly700
Reassembly700
Operation Check701
TDI TWO-STAGE AIR STARTER TROUBLESHOOTING GUIDE716
INGERSOLL-RAND TURBINE POWERED STARTER (M15002)717
MAINTENANCE717
Removal717
Installation717
Disassembly Tips717
Disassembly – Housing Exhaust Cover, Motor Assembly, and Motor Housing720
Disassembly – Drive Housing722
Assembly Tips724
Lubrication724
Assembly – Gear Case and Drive Housing725
Assembly – Intermediate Gear Case, Motor Housing, Motor Assembly, and Housing Exhaust Cover726
TEST AND INSPECTION PROCEDURE731
TROUBLESHOOTING CHART732
24 VDC ELECTRIC START SYSTEM (M17001)735
OPERATION735
CRANKING MOTOR735
Removal735
Installation735
CRANKING MOTOR TROUBLESHOOTING736
Preliminary Inspection736
No-Load Test736
Interpreting Results of Tests736
Disassembly737
Cleaning and Inspection737
Armature Servicing737
Field Coil Checks738
Field Coil Removal738
Solenoid Checks740
Test740
Assembly741
Pinion Clearance741
Magnetic Switch742
Removal742
Installation742
Coil Test742
ELECTRIC START SYSTEM WIRING DIAGRAMS743
HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS) (M20001C1)747
TROUBLESHOOTING THE HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS)759
ERROR CODES759
GENERAL INFORMATION747
TIPS FOR OPERATION747
DECK MOUNTED LIGHTS748
OPERATION AND FUNCTIONS748
DISPLAY LOGIC748
METRIC/SHORT TON SELECTION748
DATA STORAGE LOGIC748
DATA PRINT OUT749
CLEAR MEMORY749
SETTING THE TIME OF DAY749
CALIBRATING THE PAYLOAD METER750
To perform calibration:750
DIMMING THE PAYLOAD METER DISPLAY750
ERROR CODES750
SERVICING THE PAYLOAD METER750
Payload Meter Removal750
Payload Meter Installation750
REPLACING PRINTER PAPER750
Replacing Paper751
Troubleshooting Paper Printer751
REPLACEMENT OF PRINTER MODULE751
Printer Module Removal751
Printer Module Installation752
BATTERY (P/N EC2453)753
Removal753
Installation753
PRESSURE SENSOR753
To Perform A Sensor Check:753
Removal754
Installation754
INCLINOMETER754
Removal754
Installation754
RELAYS AND DATA STORAGE TRIGGER MODULE (DSTM)755
PAYLOAD METER SELF TEST FUNCTIONS755
CHECK OUT PROCEDURE756
Deck Mounted Lights756
Pressure Sensor Location756
Error Codes756
Data storage trigger module757
Inclinometer757
Body Up Switch757
ON-BOARD WEIGHING SYSTEM SCHEMATIC758
ON-BOARD WEIGHING SYSTEM EXPANDED MEMORY BOX (M20001C3)763
DOWNLOAD763
ANALYSIS763
Tips For Operation763
GETTING STARTED764
Installing The Software764
INITIAL START UP OF THE EXPANDED MEMORY BOX764
COMMON PROCEDURES765
DOWNLOAD PROGRAM766
Payload Box766
Download from Box767
Set Date and Time767
Clear Box Data768
SPECIAL769
Set Max Loads769
Clear Meter770
Box Info770
Set Truck Number771
View Data in Box771
Set Comm Port772
HELP772
ANALYSIS PROGRAM773
ANALYSIS773
Data Tables774
Graphics774
Print Report775
SETUP MENU775
PRINTER CHART776
HELP MENU777
PAYLOAD DATA778
SERVICE780
Removal780
Installation780
Disassembly780
Battery Replacement781
Assembly781
Wire Connections781
TROUBLESHOOTING EXPANDED MEMORY BOX782
DETROIT DIESEL ELECTRONIC ENGINE CONTROLS ABBREVIATIONS201
DDEC II ELECTRONIC ENGINE CONTROL (M21001)783
DDEC III ELECTRONIC ENGINE CONTROL (M21002)789
SECTION N OPERATOR’S CAB INDEX795
TRUCK CAB797
TRUCK CAB797
Removal797
Installation797
DOOR WINDOW SERVICE798
Removal799
Installation799
Disassembly799
Assembly799
CAB DOOR799
Removal799
Installation799
Door Adjustment799
Door Latch799
Removal799
Installation800
Disassembly800
Assembly800
WINDSHIELD AND REAR WINDOW SERVICE801
Removal801
Installation801
CAB COMPONENTS803
WINDSHIELD WIPER – AIR OPERATED803
Removal803
Installation803
Disassembly803
Cleaning and Inspection803
Assembly803
WIPER CONTROL VALVE804
Removal804
Installation804
ELECTRIC WINDSHIELD WIPER805
Removal805
Installation805
WINDSHIELD WASHER806
Operation806
Service806
AIR HORN806
OPERATOR COMFORT807
OPERATOR SEAT807
Adjustment807
Removal807
Installation807
Disassembly808
Inspection808
Assembly808
HEATER810
WATER CONTROL VALVE810
BLOWER AND HEATER CORE810
Removal810
Installation811
Disassembly812
Assembly812
HEATER COVER813
Installation813
FILTER813
Service813
OPERATOR CONTROLS815
STEERING COLUMN815
Removal815
Disassembly815
Cleaning and Inspection818
Assembly818
Installation815
Cleaning and Inspection818
Assembly818
THROTTLE PEDAL (1, Figure 5-9)820
BRAKE PEDAL (2, Figure 5-9)820
DIMMER SWITCH (3, Figure 5-9)820
DYNAMIC RETARDING PEDAL (4, Figure 5-9)820
HOIST CONTROL VALVE (5, Figure 5-9)821
OPERATOR CAB CENTER CONSOLE (6-11, Figure 5-9)821
Selector Switch (6)821
Engine Shutdown Switch (7)821
Engine Idle Switch (8) (Not Functional W/Statex III & Fuel Enhancement)821
12vdc Power Supply (9)821
Computer Diagnostic Port (10)821
Data Store Switch (11)821
INSTRUMENT PANEL822
INSTRUMENT PANEL824
INSTRUMENTS AND INDICATORS824
(1) KEY SWITCH824
(2) ENGINE SHUTDOWN (OPTIONAL)824
(3) WINDSHIELD WIPER/WASHER SWITCH824
(4) LIGHT SWITCH825
(5) ENGINE STARTING AID (OPTIONAL)825
(6) LADDER LIGHT SWITCH825
(7) MANUAL BACKUP LIGHT SWITCH825
(8) FOG LIGHTS (OPTIONAL)825
(9) HIGH-MOUNTED HEADLIGHTS (OPTIONAL)825
(10) PANEL LIGHT DIMMER825
(11) WATER TEMPERATURE GAUGE825
(12) ENGINE OIL PRESSURE GAUGE825
(13) AIR PRESSURE GAUGE825
(14) SPEEDOMETER825
(15) LEFT TURN SIGNAL INDICATOR825
(16) HIGH BEAM INDICATOR826
(17) RIGHT TURN SIGNAL INDICATOR826
(18) VOLTMETER826
(19) WARNING DECAL826
(20) BLANK826
(21) TACHOMETER826
CAUTION INDICATOR LIGHTS826
(22) DYNAMIC RETARDING826
(23) BODY UP826
(24) SERVICE BRAKE826
(25) PARKING BRAKE826
(26) ACCUMULATOR BOOSTER (OPTIONAL)826
(27) MANUAL BACK UP LIGHT826
(28) LOW FUEL (OPTIONAL)826
(29) HIGH PRESSURE FILTER (Optional)827
(30) ENGINE CHECK MAIN (“DDEC” Electronic Engine Controls or Cummins Engines Equipped With Centry™ Fuel Control)827
(31) Engine Check Second (Used Only with “DDEC II” – Controlled Engine)827
(32) Battery Check (“DDEC” – Controlled Engines Only)827
(33) CIRCUIT BREAKER TRIPPED827
(34) PARKING BRAKE CONTROL827
(35) SECONDARY BRAKE CONTROL827
(36) DRY ROAD/SLIPPERY ROAD SWITCH828
(37) WHEEL BRAKE LOCK828
RETARD SPEED CONTROLS (RSC) (38, 39, & 40, FIGURE 5-11)828
(38) RETARD SPEED CONTROL INDICATOR828
(39) RETARD SPEED CONTROL (RSC) SWITCH828
(40) RSC ADJUST DIAL828
(41) OVERRIDE PUSHBUTTON829
(42) WARNING DECAL829
(43) LOW STEERING PRESSURE829
(44) LOW ACCUMULATOR PRECHARGE830
(45) HIGH HYDRAULIC OIL TEMPERATURE (OPTIONAL)830
(46) LOW HYDRAULIC TANK LEVEL (OPTIONAL)830
(47) HIGH COOLANT TEMPERATURE (Not Used With “Flight/Engine Saver” or “DDEC”- Controlled Engine)830
(48) LOW COOLANT LEVEL (Not Used With “DDEC” – Engine)830
(49) LOW OIL PRESSURE (Not Used With “Engine Saver” or “DDEC” – Engine)830
(50) LOW OIL LEVEL (OPTIONAL)831
(51) Used ONLY With Electronic-Controlled Engine Options831
ENGINE MONITOR (Used for “Flight/Engine Saver” Option)831
ENGINE MONITOR MAIN – (“DDEC”)831
(52) CRANKCASE PRESSURE WARNING LIGHT (Used Only for Detroit Diesel Engine Without DDEC Controls)831
(53) LOW BRAKE PRESSURE831
(54) ENGINE MONITOR SECOND (Used Only With “DDEC II” Electronic- Controlled Engine Option)831
(55) ELECTRIC SYSTEM FAULT831
(56) MOTOR BLOWER OFF831
(57) HIGH MOTOR TEMPERATURE (OPTIONAL)831
(58) BLANK832
(59) LAMP TEST and Cummins Centry™ Diagnostic Test Switch (if equipped)832
(60) HEATER TEMPERATURE CONTROL LEVER832
(61) DEFROSTER/HEAT CONTROL LEVER832
(62) OUTSIDE/INSIDE AIR CONTROL LEVER832
(63) AIR CONDITIONER CONTROL (OPTIONAL)832
(64) FAN CONTROL KNOB832
(65) AIR CLEANER SERVICE VACUUM GAUGE833
(66) FUEL LEVEL GAUGE (OPTIONAL)833
(67) HOURMETER833
(68) OVERSPEED ALARM HORN (OPTIONAL)833
(69) CIRCUIT BREAKERS833
CENTRY™ FUEL SYSTEM DIAGNOSTICS – CUMMINS ENGINE ONLY -834
DETERMINING “FAULT” CODES834
EXITING THE DIAGNOSTICS MODE835
SECTION P LUBRICATION AND SERVICE INDEX837
LUBRICATION AND SERVICE839
HYDRAULIC TANK SERVICE839
Adding Oil839
LUBRICATION CHART840
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS841
50 HOUR LUBRICATION AND MAINTENANCE CHECKS843
100 HOUR LUBRICATION AND MAINTENANCE CHECKS844
250 HOUR LUBRICATION AND MAINTENANCE CHECKS845
500 HOUR LUBRICATION AND MAINTENANCE CHECKS846
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS847
5000 HOURS LUBRICATION AND MAINTENANCE CHECKS848
10000 HOURS LUBRICATION AND MAINTENANCE CHECKS848
MOTORIZED WHEEL MAINTENANCE SCHEDULE849
SECTION Q ALPHABETICAL INDEX853
SECTION R SYSTEM SCHEMATICS INDEX857
AIR SYSTEM SCHEMATIC HA195859
AIR SYSTEM SCHEMATIC HA198860
BRAKE SYSTEM HYDRAULIC SCHEMATIC HH313861
HYDRAULIC SYSTEM SCHEMATIC HUSCO VALVE HH309862
Sheet 1862
Sheet 2863
Sheet 3864
RETARD CONTROL PANEL FOR STATEX III HE378865
ACCEL INTERFACE PANEL FOR STATEX III HE379866
STATEX III POWER AND EXCITATION SCHEMATIC HE376867
Sheet 1867
Sheet 2868
Sheet 3869
ELECTRICAL SCHEMATIC HE400870
Sheet 1870
Sheet 2871
Sheet 3872
Sheet 4873
Sheet 5874
Sheet 6875
Sheet 7876
Sheet 8877
Sheet 9878
Sheet 10879
Sheet 11880
Sheet 12881
Sheet 13882
Sheet 14883
Sheet 15884

IMAGES PREVIEW OF THE MANUAL:

S.M 18/12/24