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Komatsu 630E Dump Truck Shop Manual SN AFE42-M, AFE46-U and up – PDF DOWNLOAD
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Komatsu 630E Dump Truck Shop Manual
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AFE46-U and up
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Description
Komatsu 630E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 630E Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 630E
Serial Number: AFE42-M, AFE46-U and up
Book Code: DG675
Language: English
Pages: 885
File Format: Portable Document Format (PDF)
TABLE OF CONTENTS:
Komatsu 630E Dump Truck Shop Manual
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 INDEX.................................................................................................................101
24 VDC ELECTRIC SUPPLY SYSTEM.................................................................................................................103
ELECTRICAL SYSTEM DESCRIPTION.............................................................................................................103
BATTERY...................................................................................................................................103
Maintenance and Service...............................................................................................................103
Troubleshooting.......................................................................................................................103
BATTERY CHARGING SYSTEM...................................................................................................................105
General Description...................................................................................................................105
Operating Principles..................................................................................................................105
Energizing Speed......................................................................................................................105
Rated Voltage.........................................................................................................................106
Magnetizing The Rotor.................................................................................................................106
INTEGRAL CHARGING SYSTEM (Battery Charging Alternator)....................................................................................107
Troubleshooting Procedures............................................................................................................107
Integral Charging System Repair.......................................................................................................107
Regulator Check.......................................................................................................................108
Rectifier Bridge Check (Omit for Overcharged Battery).................................................................................108
Field Coil Checks.....................................................................................................................108
Diode Trio Check......................................................................................................................108
Stator Checks (Omit for Overcharged Battery)..........................................................................................109
Disassembly (Refer to Figure 2-10)....................................................................................................109
Reassembly............................................................................................................................110
24 VDC ELECTRICAL SYSTEM COMPONENTS...........................................................................................................113
ALARM INDICATING DEVICE (AID) SYSTEM......................................................................................................113
BODY-UP SWITCH............................................................................................................................115
Adjustment............................................................................................................................115
Service...............................................................................................................................115
HOIST LIMIT SWITCH........................................................................................................................115
Adjustment............................................................................................................................115
Service...............................................................................................................................115
GROUND LEVEL SHUTDOWN.....................................................................................................................116
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 BOARDS......................................................................................................................117
Description...........................................................................................................................118
Service...............................................................................................................................118
RELAY BOARD DESCRIPTIONS..................................................................................................................120
Relay Board 1 Turn Signal.............................................................................................................120
Relay Board 2 Payload Meter (Optional)................................................................................................120
Relay Board 3 Stop Lights.............................................................................................................120
Relay Board 4 Parking Brake...........................................................................................................120
Relay Board 5 Head Lights.............................................................................................................121
Relay Board 6 Auxiliary Panel.........................................................................................................121
DIODE BOARDS..............................................................................................................................122
Diode Board 1.........................................................................................................................122
Diode Board 2.........................................................................................................................123
CIRCUIT BREAKERS..........................................................................................................................124
SECTION E ELECTRICAL PROPULSION COMPONENTS INDEX..................................................................................................125
ELECTRICAL PROPULSION COMPONENTS..............................................................................................................127
GENERAL SYSTEM DESCRIPTION................................................................................................................127
CONTROL SYSTEM............................................................................................................................127
System Operation......................................................................................................................128
17FL275 PANEL.............................................................................................................................129
COMPUTER DESCRIPTION..................................................................................................................131
SOFTWARE..............................................................................................................................131
CARD REPLACEMENT..........................................................................................................................130
Removal...............................................................................................................................130
Installation..........................................................................................................................130
Card Repair...........................................................................................................................130
COMPUTER DESCRIPTION......................................................................................................................131
Microprocessor........................................................................................................................131
Download Capability...................................................................................................................131
SOFTWARE..................................................................................................................................131
Base Monitor Program..................................................................................................................131
Runtime Monitor Program - OBJ Running Code............................................................................................131
Configuration Software - CFG..........................................................................................................132
PTU - Portable Test Unit Code.........................................................................................................132
System Regulation.....................................................................................................................132
Propulsion............................................................................................................................132
Retarding.............................................................................................................................133
2-DIGIT DISPLAY PANEL.....................................................................................................................134
The Coded Number......................................................................................................................134
Events................................................................................................................................134
Frames................................................................................................................................135
Windows...............................................................................................................................135
System Categories.....................................................................................................................135
Limits On Resetting Faults............................................................................................................135
Na Faults.............................................................................................................................136
Event Sequence........................................................................................................................136
Resetting Events......................................................................................................................136
Event Descriptions....................................................................................................................136
Subcode Descriptions..................................................................................................................136
2-DIGIT DISPLAY PANEL CODES...............................................................................................................137
PORTABLE TEST UNIT (PTU)..................................................................................................................146
DESCRIPTION...........................................................................................................................146
OPERATIONAL HINTS.....................................................................................................................146
SOFTWARE INSTALLATION PREPARATION.....................................................................................................147
Deleting Prior Software Versions..................................................................................................147
Computer Boot File Editing........................................................................................................147
SOFTWARE INSTALLATION ON PTU..........................................................................................................148
THE MAIN MENU.........................................................................................................................149
PTU SOFTWARE MENU TREE................................................................................................................150
CONFIGURATION (CFG) FILE CONVERSION...................................................................................................151
Conversion Procedure..............................................................................................................151
STATEX CONFIGURATION FILES............................................................................................................157
“Change Ptu Password”.............................................................................................................167
PROGRAMMING THE TRUCK.................................................................................................................168
Connect PTU to the Truck..........................................................................................................168
Select Configuration File.........................................................................................................168
Activate The PTU Mode.............................................................................................................168
Check Object Code Version.........................................................................................................169
Download Configuration Files......................................................................................................170
Date And Time.....................................................................................................................171
Event Data........................................................................................................................172
STATISTICAL DATA......................................................................................................................174
“View Counters”...................................................................................................................174
“View Profiles”...................................................................................................................174
“Upload Statistical Data To A File”...............................................................................................174
Statistical Data Codes - Counters.................................................................................................175
STATISTICAL DATA CODES - PROFILES.....................................................................................................181
Truck Specific Information........................................................................................................185
Temporary Truck Settings..........................................................................................................186
MISCELLANEOUS FEATURES................................................................................................................187
Saving Data.......................................................................................................................187
Ptu Abbreviations.................................................................................................................187
OTHER MENU SELECTIONS.................................................................................................................187
PANEL WIRING..............................................................................................................................130
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS................................................................................................189
ALTERNATOR................................................................................................................................189
ELECTRIC WHEEL MOTORS.....................................................................................................................189
RETARDING GRIDS...........................................................................................................................189
AIR THROTTLE/ELECTRONIC RETARD CONTROL....................................................................................................190
Acceleration Switch [AS]..............................................................................................................190
Range Adjustment......................................................................................................................190
Differential Adjustment...............................................................................................................190
Removal...............................................................................................................................190
Installation..........................................................................................................................190
Disassembly and Assembly..............................................................................................................191
Adjustment Procedure (On Bench).......................................................................................................191
Adjustment Procedure (On Truck).......................................................................................................191
PROPEL/RETARD INTERFACE PANELS (Non-Fuel Saver Only)......................................................................................191
ACC Panel Operation...................................................................................................................191
RET Panel Operation...................................................................................................................191
ELECTRONIC ACCELERATOR AND RETARD PEDALS..................................................................................................192
Removal...............................................................................................................................192
Installation..........................................................................................................................192
Disassembly...........................................................................................................................192
Assembly..............................................................................................................................192
COOLING BLOWER WARNING SYSTEM.............................................................................................................193
Operation.............................................................................................................................193
Test..................................................................................................................................193
Removal...............................................................................................................................193
Installation..........................................................................................................................193
ELECTRICAL CONTROL CABINET................................................................................................................194
ABBREVIATION FOR STATEX III ELECTRIC DRIVE COMPONENTS.....................................................................................200
DETROIT DIESEL ELECTRONIC ENGINE CONTROLS ABBREBIATIONS...................................................................................201
CARD IDENTIFICATION LIST GE17FL275 PANEL, STATEX III......................................................................................201
CHECKOUT PROCEDURE STATEX III ELECTRICAL SYSTEM...............................................................................................203
GENERAL INFORMATION.......................................................................................................................205
COMMUNICATIONS PORT CHECK.................................................................................................................206
PTU Hookup............................................................................................................................206
1.0 SEQUENCE TESTS - (Engine not running).................................................................................................208
1.1 Throttle System Check and Adjustment..............................................................................................209
1.1.1 Electronic Throttle System. (Williams electronic foot pedal, Dresser ACC/RET Interface Circuit and Pedal Detector Card).....209
1.1.2 Electronic Throttle System (Fuel Saver System)..............................................................................210
1.2 Retard System Check and Adjustment................................................................................................212
1.2.1 Williams Electronic Retard Pedal and Dresser ACC/RET or RET Interface Box...................................................212
1.2.2 Electronic Retard Pedal; Fuel Saver Equipped Trucks and Current Production..................................................213
1.3 Reverser and Propulsion Contactors Check..........................................................................................215
1.4 Propulsion Lockout Test (DDEC & MTU Engine Trucks Only)...........................................................................216
1.5 Retard Contactors Operation Check.................................................................................................217
1.6 Ground Fault Sensing Check........................................................................................................217
1.7 Ground Fault in Retard Operation Check............................................................................................217
1.8 Override Operation Check..........................................................................................................218
1.9 Anti-Reversal Function (AR) Check.................................................................................................219
1.10 Overspeed Retard Operation Check.................................................................................................219
1.11 Hoist Interlock Operation Check..................................................................................................220
1.12 Motor Blower Fault Light Operation Check.........................................................................................221
2.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL..................................................................................222
2.1 Setup Manual Digital Input/Output Test on PTU.....................................................................................222
2.2 Digital Input Checks..............................................................................................................223
2.3 Digital Output Checks.............................................................................................................225
3.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL..........................................................................................228
3.1 Setup Analog Input Monitor Screen on PTU..........................................................................................228
3.2 Analog Input Checks...............................................................................................................229
3.3 Frequency Input Checks............................................................................................................236
4.0 SPEED EVENT CHECKS....................................................................................................................238
4.1 Single Speed Overspeed Truck - Overspeed Settings Check...........................................................................239
4.2 Two Speed Overspeed Truck (Empty Truck) - Overspeed Settings Check................................................................239
4.3 Two Speed Overspeed Truck (Loaded Truck) - Overspeed Settings Check...............................................................239
4.4 Other Speed Events Checks.........................................................................................................239
5.0 RETARD SPEED CONTROL SYSTEM CHECK.....................................................................................................241
5.1 Overspeed Pickup and Dropout Check................................................................................................241
5.2 Retard Pot Maximum Setting Check..................................................................................................242
5.3 Retard Pot Minimum Setting Check..................................................................................................242
5.4 Accelerator Pedal Override of Retard Speed Control................................................................................242
6.0 LOAD TEST USING TRUCK RETARD GRIDS....................................................................................................243
6.1 Load Test.........................................................................................................................244
7.0 MOTOR FIELD CURRENT CHECK IN RETARDING................................................................................................245
7.1 Retard Check......................................................................................................................245
8.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT...........................................................................................246
8.1 Brake System Interlocks Check.....................................................................................................246
8.2 Blower Loss Pressure Switch Adjustment............................................................................................247
8.3 SYNC Transformer Checkout.........................................................................................................247
8.4 Power Contactor Position Sensor Adjustment........................................................................................247
8.5 Battery Boost Adjustment..........................................................................................................248
8.6 Isolation amplifier & voltage module test.........................................................................................248
8.6.1 Voltage Measuring Module Test (VMM1 and VMM2)...............................................................................248
8.6.2 ISOA3, ISOA4, ISOA5, ISOA6, ISOA-7, and ISOA-8 Test.........................................................................249
8.7 Motor Rotation Test...............................................................................................................249
8.8 Ground Fault Checks...............................................................................................................250
9.0 MISCELLANEOUS CHARTS..................................................................................................................251
9.1 Wheel Motor Gear Ratios...........................................................................................................251
9.2 Maximum Allowable Truck Speeds....................................................................................................252
9.3 Engine Options....................................................................................................................253
SECTION G REAR AXLE SPINDLES AND WHEELS INDEX.....................................................................................................255
TIRES AND RIMS................................................................................................................................257
FRONT TIRES AND RIMS......................................................................................................................258
Removal...............................................................................................................................258
Installation..........................................................................................................................258
REAR TIRE AND RIM.........................................................................................................................259
Removal...............................................................................................................................259
Installation..........................................................................................................................260
RIM.......................................................................................................................................260
Tire Removal..........................................................................................................................260
Tire Installation.....................................................................................................................261
FRONT WHEEL HUB AND SPINDLE...................................................................................................................263
FRONT WHEEL HUB...........................................................................................................................263
Removal...............................................................................................................................263
Installation..........................................................................................................................264
Disassembly...........................................................................................................................265
Cleaning and Inspection...............................................................................................................266
Assembly..............................................................................................................................266
Wheel Bearing Adjustment..............................................................................................................268
Field Adjustment......................................................................................................................268
STEERING CYLINDERS AND TIE ROD............................................................................................................270
Removal...............................................................................................................................270
Installation..........................................................................................................................271
Bearing Replacement...................................................................................................................271
TOE-IN ADJUSTMENT.........................................................................................................................272
(Bias Ply Tires)......................................................................................................................272
(Radial Tires)........................................................................................................................272
REAR AXLE HOUSING ATTACHMENT..................................................................................................................273
HITCH PIN.................................................................................................................................273
Removal...............................................................................................................................273
Installation..........................................................................................................................273
PIVOT PIN BEARING.........................................................................................................................274
Disassembly...........................................................................................................................274
Assembly..............................................................................................................................274
PIVOT EYE REPAIR..........................................................................................................................275
Removal...............................................................................................................................275
Installation..........................................................................................................................275
ANTI-SWAY BAR.............................................................................................................................276
Removal...............................................................................................................................276
Installation..........................................................................................................................276
Disassembly...........................................................................................................................276
Cleaning and Inspection...............................................................................................................276
Assembly..............................................................................................................................276
REAR AXLE HOUSING.............................................................................................................................277
REAR AXLE HOUSING.........................................................................................................................277
WHEEL MOTOR...............................................................................................................................277
REAR AXLE HOUSING BUMPER PAD..............................................................................................................278
SECTION H HYDRAIR II SUSPENSIONS INDEX............................................................................................................279
FRONT SUSPENSION..............................................................................................................................281
FRONT SUSPENSION..........................................................................................................................281
Removal...............................................................................................................................281
Installation..........................................................................................................................282
Disassembly...........................................................................................................................285
Cleaning and Inspection...............................................................................................................285
Assembly..............................................................................................................................286
REAR SUSPENSION...............................................................................................................................289
REAR SUSPENSION...........................................................................................................................289
Removal...............................................................................................................................289
Installation..........................................................................................................................290
Disassembly...........................................................................................................................290
Cleaning and Inspection...............................................................................................................292
Assembly..............................................................................................................................292
OILING AND CHARGING PROCEDURES................................................................................................................295
GENERAL...................................................................................................................................295
EQUIPMENT LIST............................................................................................................................295
HYDRAIR® CHARGING KIT.....................................................................................................................295
Installation of Charging Kit..........................................................................................................295
Removal of Charging Kit...............................................................................................................296
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS.........................................................................................296
FRONT SUSPENSION..........................................................................................................................297
Front Suspension Oiling...............................................................................................................297
Front Suspension Nitrogen Charging....................................................................................................298
REAR SUSPENSION...........................................................................................................................299
Rear Suspension Oiling................................................................................................................299
Rear Suspension Nitrogen Charging.....................................................................................................300
SECTION J BRAKE CIRCUIT INDEX.....................................................................................................................303
BRAKE CIRCUIT.................................................................................................................................305
Operation.................................................................................................................................305
BRAKE CIRCUIT COMPONENT DESCRIPTION...........................................................................................................305
Normal Brake Application..................................................................................................................305
Slippery Road Operation...................................................................................................................307
Wheel Brake Lock Operation................................................................................................................307
Secondary Brake Switch Operation..........................................................................................................307
Automatic Emergency Brake Application.....................................................................................................307
Parking Brake.............................................................................................................................307
BRAKE CIRCUIT COMPONENT SERVICE...............................................................................................................309
DUAL CONTROLLER...........................................................................................................................309
Operation Of Brake Controller Components..............................................................................................309
Removal...............................................................................................................................310
Installation..........................................................................................................................310
Service...............................................................................................................................315
Disassembly...........................................................................................................................315
Cleaning and Inspection...............................................................................................................316
Assembly..............................................................................................................................317
BENCH ADJUSTMENT..........................................................................................................................318
Equipment Required:...................................................................................................................318
Adjustments...........................................................................................................................319
HYDRAULIC BRAKE CONTROLLER TROUBLESHOOTING................................................................................................321
HYDRAULIC BRAKE ACCUMULATORS..............................................................................................................325
Brake Accumulator Bleed Down Procedure................................................................................................325
Removal...............................................................................................................................325
Installation..........................................................................................................................325
Disassembly...........................................................................................................................325
Cleaning and Inspection...............................................................................................................326
Assembly..............................................................................................................................327
Charging Procedure....................................................................................................................328
DIFFERENTIAL PRESSURE MANIFOLD............................................................................................................329
Removal...............................................................................................................................329
Installation..........................................................................................................................329
Disassembly...........................................................................................................................329
Cleaning and Inspection...............................................................................................................330
Assembly and Initial Adjustment.......................................................................................................330
Final Adjustment......................................................................................................................331
PILOTED SINGLE CONTROLLER.................................................................................................................331
Removal...............................................................................................................................331
Installation..........................................................................................................................332
Disassembly...........................................................................................................................332
Cleaning and Inspection...............................................................................................................332
Assembly..............................................................................................................................332
Bench Test............................................................................................................................332
Equipment Needed:.....................................................................................................................333
Set-Up................................................................................................................................333
Adjustment............................................................................................................................333
DRY/SLIPPERY ROAD SOLENOID VALVE..........................................................................................................334
Removal...............................................................................................................................334
Installation..........................................................................................................................334
Disassembly...........................................................................................................................335
Cleaning and Inspection...............................................................................................................335
Assembly..............................................................................................................................335
BRAKE CIRCUIT CHECK OUT AND ADJUSTMENT PROCEDURE..............................................................................................337
BRAKE CIRCUIT COMPONENT LEAKAGE TEST......................................................................................................337
Accumulators..........................................................................................................................337
Dual Controller and Piloted Single Controller.........................................................................................338
Dry/Slippery Road Valve...............................................................................................................338
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT.....................................................................................................339
FRONT WHEEL SPEED DISC BRAKES.................................................................................................................343
CARLISLE WHEEL SPEED DISC BRAKES..........................................................................................................343
BRAKE CALIPERS........................................................................................................................343
Lining Replacement................................................................................................................343
Brake Caliper Removal.............................................................................................................344
Brake Caliper Installation........................................................................................................345
Brake Caliper Disassembly.........................................................................................................345
Inspection........................................................................................................................345
Brake Caliper Assembly............................................................................................................346
BRAKE CALIPER BENCH TEST..............................................................................................................347
BRAKE BLEEDING PROCEDURE..............................................................................................................347
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.....................................................................................348
Front Brake Conditioning..........................................................................................................348
Temporary Disconnect Procedures For Rear Brakes...................................................................................348
Temporary Disconnect Procedures for Disabling Rear Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks...............349
Temporary Disconnect Procedures for Disabling Rear Brakes For Model 830E HAULPAK® Trucks......................................349
SPECIAL TOOLS.........................................................................................................................350
ROCKWELL WHEEL SPEED FRONT DISC BRAKES....................................................................................................351
BRAKE CALIPER.........................................................................................................................351
BRAKE LINING..........................................................................................................................355
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.....................................................................................355
TEMPORARY DISCONNECT PROCEDURES FOR REAR BRAKES.......................................................................................356
BRAKE BLEEDING PROCEDURES.............................................................................................................358
REAR ARMATURE SPEED DISC BRAKES...............................................................................................................359
CARLISLE ARMATURE SPEED REAR DISC BRAKES..................................................................................................359
BRAKE CALIPERS........................................................................................................................359
Lining Replacement................................................................................................................359
Caliper Removal...................................................................................................................360
Inspection........................................................................................................................362
Installation......................................................................................................................363
Disassembly of Brake Calipers.....................................................................................................364
Inspection........................................................................................................................366
Caliper Assembly..................................................................................................................366
BRAKE CALIPER BENCH TEST..............................................................................................................367
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.....................................................................................368
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE.....................................................................................368
General.......................................................................................................................368
Carlisle Armature Speed Disc Brakes Conditioning (Burnishing) Rear Brakes.....................................................368
BLEEDING PROCEDURE................................................................................................................369
TEMPORARY DISCONNECT PROCEDURES FOR DISABLING FRONT BRAKES........................................................................369
Temporary Disconnect Procedures for Disabling Front Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks..............370
Temporary Disconnect Procedures for Disabling Front Brakes For Model 830E HAULPAK® Trucks.....................................370
ROCKWELL ARMATURE SPEED REAR DISC BRAKES..................................................................................................371
REAR BRAKES...........................................................................................................................371
CALIPER, DISC AND PARKING BRAKE.......................................................................................................371
FUNCTIONAL TEST OF PISTON ASSEMBLY....................................................................................................377
BRAKE LINING..........................................................................................................................383
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE.........................................................................................385
BLEEDING PROCEDURE....................................................................................................................386
REAR DISC PARKING BRAKE.......................................................................................................................397
CARLISLE DISC PARKING BRAKE...............................................................................................................397
PARKING BRAKE OPERATION...............................................................................................................397
TRUCKS WITH ROCKWELL SERVICE BRAKES...................................................................................................397
Caliper Removal...................................................................................................................397
Caliper Installation..............................................................................................................398
TRUCKS WITH CARLISLE SERVICE BRAKES...................................................................................................399
Caliper Removal...................................................................................................................399
Caliper Installation..............................................................................................................399
Lining Replacement................................................................................................................400
Caliper Disassembly...............................................................................................................400
Inspection........................................................................................................................400
Caliper Assembly..................................................................................................................401
BRAKE CALIPER BENCH TEST..............................................................................................................402
PARKING BRAKE BLEEDING................................................................................................................402
CONDITIONING PROCEDURE FOR DISC PARKING BRAKE.........................................................................................402
500 HOUR SERVICE GUIDE FOR DISC PARKING BRAKE.........................................................................................403
ROCKWELL DISC PARKING BRAKE...............................................................................................................405
CALIPER STYLE IDENTIFICATION..............................................................................................................405
REMOVAL...............................................................................................................................406
INSTALLATION..........................................................................................................................406
PARKING BRAKE ADJUSTMENT (SCL 70).....................................................................................................406
PARKING BRAKE ADJUSTMENT (SCL15)......................................................................................................408
PARK BRAKE CALIPER DISASSEMBLY........................................................................................................409
CLEANING AND INSPECTION...............................................................................................................410
PARK BRAKE CALIPER ASSEMBLY...........................................................................................................411
PARK BRAKE LINING REPLACEMENT.............................................................................................................411
PARK BRAKE BURNISH PROCEDURE..........................................................................................................411
BRAKE BLEEDING PROCEDURE..............................................................................................................411
SECTION K AIR SYSTEM INDEX........................................................................................................................413
AIR SYSTEM OPERATION..........................................................................................................................415
AIR COMPONENT DESCRIPTION.................................................................................................................416
Air Compressor........................................................................................................................416
Air Starter Circuit (If Equipped*)....................................................................................................416
Air Dryer/Aftercooler.................................................................................................................416
Air Dryer (If Equipped)...............................................................................................................416
Aftercooler (If Equipped).............................................................................................................416
Check Valve...........................................................................................................................417
Main Air Tank.........................................................................................................................417
Safety Valve..........................................................................................................................417
Automatic/Manual Drain Valve..........................................................................................................417
Air Governor..........................................................................................................................418
Radiator Pressure Regulating Valve (Detroit Diesel Engine Only).......................................................................418
90 psi (622 kPa) Air Regulating Valve For Contact Relays..............................................................................418
Air System Lubricator (If Equipped)...................................................................................................419
Shop Air Quick Disconnect.............................................................................................................419
AIR SYSTEM COMPONENT REPAIR...................................................................................................................421
AIR COMPRESSOR SERVICE....................................................................................................................421
AIR DRYER/AFTERCOOLER.....................................................................................................................421
SAFETY VALVE..............................................................................................................................421
Operating Test........................................................................................................................421
AIR GOVERNOR..............................................................................................................................421
Disassembly...........................................................................................................................421
Cleaning and Inspection...............................................................................................................422
Assembly..............................................................................................................................422
Adjustment............................................................................................................................422
Leakage Tests.........................................................................................................................422
AUTOMATIC/MANUAL DRAIN VALVE..............................................................................................................423
Removal...............................................................................................................................423
Installation..........................................................................................................................423
Disassembly...........................................................................................................................423
Cleaning and Inspection...............................................................................................................423
Assembly..............................................................................................................................424
RADIATOR PRESSURE REGULATING VALVE (Detroit Diesel Engine Only)...........................................................................424
Removal...............................................................................................................................424
Installation and Adjustment...........................................................................................................424
Disassembly...........................................................................................................................424
Cleaning and Inspection...............................................................................................................425
Assembly..............................................................................................................................425
AIR PRESSURE REGULATING VALVE FOR CONTACT RELAYS [90 psi (622 kPa)].......................................................................425
Removal...............................................................................................................................425
Installation..........................................................................................................................425
Disassembly...........................................................................................................................425
Cleaning and Inspection...............................................................................................................425
Assembly..............................................................................................................................426
Adjustment............................................................................................................................426
AIR STARTER CIRCUIT (If Equipped).........................................................................................................426
AIR SYSTEM LUBRICATOR (If Equipped).......................................................................................................426
Service...............................................................................................................................426
Adjustment............................................................................................................................426
AIR STARTER CIRCUIT...........................................................................................................................427
DUMP VALVE................................................................................................................................428
AIR START SOLENOID VALVE..................................................................................................................428
AIR STARTER...............................................................................................................................428
AIR STARTER COMPONENT REPAIR..............................................................................................................429
AIR START SOLENOID VALVE..................................................................................................................429
Removal...............................................................................................................................429
Installation..........................................................................................................................429
Disassembly...........................................................................................................................429
Cleaning and Inspection...............................................................................................................429
Service...............................................................................................................................429
Assembly..............................................................................................................................429
DUMP VALVE................................................................................................................................429
Removal...............................................................................................................................429
Installation..........................................................................................................................430
AIR STARTER...............................................................................................................................430
Removal...............................................................................................................................430
Installation..........................................................................................................................430
Disassembly Tips......................................................................................................................430
Disassembly...........................................................................................................................430
Assembly..............................................................................................................................433
Test and Inspection Procedure.........................................................................................................436
AIR STARTER LUBRICATOR....................................................................................................................430
Removal...............................................................................................................................430
Installation..........................................................................................................................430
TROUBLESHOOTING CHART.........................................................................................................................437
THROTTLE TREADLE VALVE........................................................................................................................439
COMPONENT DESCRIPTION.....................................................................................................................439
Treadle Valve.........................................................................................................................439
Service...............................................................................................................................439
COMPONENT REPAIR..........................................................................................................................439
Removal...............................................................................................................................439
Installation..........................................................................................................................439
Disassembly...........................................................................................................................439
Inspection............................................................................................................................440
Assembly..............................................................................................................................441
SECTION L HYDRAULIC SYSTEM INDEX..................................................................................................................443
HYDRAULIC SYSTEM..............................................................................................................................445
HYDRAULIC SYSTEM OPERATION................................................................................................................445
COMPONENT DESCRIPTION.....................................................................................................................445
High Pressure Filters.................................................................................................................445
Hydraulic Pump........................................................................................................................445
Hydraulic Tank........................................................................................................................446
HYDRAULIC SYSTEM (With Trolley Assisted Option)...........................................................................................447
HYDRAULIC SYSTEM DESCRIPTION..............................................................................................................447
HYDRAULIC SYSTEM COMPONENT REPAIR.............................................................................................................449
HYDRAULIC PUMP............................................................................................................................449
Removal...............................................................................................................................449
Installation..........................................................................................................................450
Pump Disassembly......................................................................................................................450
Pump Assembly.........................................................................................................................451
Cartridge Disassembly.................................................................................................................452
Inspection........................................................................................................................454
Cartridge Assembly....................................................................................................................455
TROUBLESHOOTING CHART.....................................................................................................................457
HYDRAULIC TANK............................................................................................................................458
Filling Instructions..................................................................................................................458
Removal...............................................................................................................................459
Installation..........................................................................................................................459
HYDRAULIC TANK STRAINER AND DIFFUSER......................................................................................................459
Removal...............................................................................................................................459
Inspect and Clean.....................................................................................................................460
Installation..........................................................................................................................460
HYDRAULIC SYSTEM FLUSHING PROCEDURE.......................................................................................................461
STEERING CIRCUIT..............................................................................................................................463
STEERING CIRCUIT OPERATION................................................................................................................463
COMPONENT DESCRIPTION.....................................................................................................................463
Steering Control Valve................................................................................................................463
Unloader Valve........................................................................................................................463
Operation.............................................................................................................................464
Bleeddown Manifold....................................................................................................................466
Bleeddown Solenoid....................................................................................................................466
Accumulators..........................................................................................................................466
High Pressure Filter..................................................................................................................466
Flow Amplifier........................................................................................................................466
FLOW AMPLIFIER SYSTEM OPERATION...........................................................................................................468
No Steer..............................................................................................................................468
Steering Left.........................................................................................................................470
Steering Right........................................................................................................................472
No Steer, External Shock Load.........................................................................................................474
STEERING CONTROL VALVE........................................................................................................................477
STEERING CONTROL VALVE....................................................................................................................477
Removal...............................................................................................................................477
Installation..........................................................................................................................477
Disassembly...........................................................................................................................478
Cleaning and Inspection...............................................................................................................479
Assembly..............................................................................................................................481
Alternate Method for Installing Centering Springs.....................................................................................481
STEERING CIRCUIT COMPONENT REPAIR.............................................................................................................485
UNLOADER VALVE............................................................................................................................485
Removal...............................................................................................................................485
Installation and Adjustment...........................................................................................................485
REBUILDING UNLOADER VALVE.................................................................................................................485
Disassembly...........................................................................................................................485
Clean and Inspect.....................................................................................................................486
Assembly..............................................................................................................................486
BLEEDDOWN MANIFOLD........................................................................................................................487
Removal...............................................................................................................................487
Adjusting Relief Valve................................................................................................................487
Testing and Adjustment................................................................................................................488
FLOW AMPLIFIER............................................................................................................................489
Removal...............................................................................................................................489
Installation..........................................................................................................................489
Disassembly...........................................................................................................................489
Assembly..............................................................................................................................492
ACCUMULATORS..............................................................................................................................493
Removal...............................................................................................................................493
Installation..........................................................................................................................493
Cleaning and Inspection...............................................................................................................494
Assembly..............................................................................................................................494
STEERING ACCUMULATOR CHARGING PROCEDURE...................................................................................................495
STEERING CYLINDERS........................................................................................................................496
Disassembly...........................................................................................................................496
Assembly..............................................................................................................................496
STEERING CIRCUIT FILTER (OPTIONAL)........................................................................................................498
Removal...............................................................................................................................498
Installation..........................................................................................................................498
STEERING CIRCUIT TEST PROCEDURE...........................................................................................................499
PRESSURE ADJUSTMENT PROCEDURE.........................................................................................................499
COMPONENT LEAKAGE TEST................................................................................................................501
TROUBLESHOOTING CHART.....................................................................................................................502
HOIST CIRCUIT.................................................................................................................................505
HOIST CIRCUIT OPERATION...................................................................................................................505
COMPONENT DESCRIPTION.....................................................................................................................506
Hydraulic Tank........................................................................................................................506
Hydraulic Pump........................................................................................................................506
High Pressure Filters.................................................................................................................506
Hoist Valve...........................................................................................................................506
Hoist Pilot Valve.....................................................................................................................507
Hoist-up Limit Solenoid...............................................................................................................508
Pilot Operated Check Valve............................................................................................................508
Hoist Valve Operation.................................................................................................................508
Float Operation.......................................................................................................................508
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 REPAIR................................................................................................................519
HOIST VALVE...............................................................................................................................519
Removal...............................................................................................................................519
Installation..........................................................................................................................520
Disassembly...........................................................................................................................520
INLET SECTION.............................................................................................................................521
Disassembly...........................................................................................................................521
Cleaning and Inspection...............................................................................................................522
Reassembly............................................................................................................................522
SPOOL SECTION.............................................................................................................................522
Disassembly...........................................................................................................................522
Cleaning and Inspection...............................................................................................................524
Reassembly............................................................................................................................524
HOIST PILOT VALVE.........................................................................................................................525
Removal...............................................................................................................................525
Installation..........................................................................................................................525
Disassembly...........................................................................................................................525
Cleaning and Inspection...............................................................................................................526
Reassembly............................................................................................................................526
HOIST CYLINDERS...........................................................................................................................527
Removal...............................................................................................................................527
Installation..........................................................................................................................528
Disassembly...........................................................................................................................528
Cleaning and Inspection...............................................................................................................530
ASSEMBLY OF QUILL AND CYLINDER............................................................................................................531
Quill Installation....................................................................................................................531
Installation Of Check Balls And Plugs In Quill........................................................................................532
Assembly of Cylinder..................................................................................................................533
HIGH PRESSURE FILTERS.....................................................................................................................534
Removal...............................................................................................................................534
Installation..........................................................................................................................534
BODY UP LIMIT SOLENOID....................................................................................................................535
PILOT OPERATED CHECK VALVE................................................................................................................535
CHECKING HOIST SYSTEM PRESSURE RELIEF VALVE...............................................................................................535
SECTION M OPTIONS AND SPECIAL TOOLS INDEX.........................................................................................................537
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
OPERATION.................................................................................................................................559
Operation.............................................................................................................................559
Components............................................................................................................................559
Description of Components.............................................................................................................559
GENERAL INSTRUCTIONS......................................................................................................................560
Lubricant Required for System.........................................................................................................560
Initial Reservoir Fill................................................................................................................560
System Priming........................................................................................................................560
SYSTEM CHECKOUT...........................................................................................................................561
24 VDC SOLID STATE TIMER CHECK............................................................................................................561
INJECTORS (SL-1 SERIES "H")...............................................................................................................562
TROUBLESHOOTING CHART.....................................................................................................................564
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM (M04002)..................................................................................567
SYSTEM ADJUSTMENT.........................................................................................................................567
PUMP......................................................................................................................................567
BLOWER DRIVE MOTOR........................................................................................................................570
BLOWER BEARING REPAIR.....................................................................................................................573
AIR CLEANER...............................................................................................................................574
WIGGINS QUICK FILL FUEL SYSTEM (M05002).......................................................................................................575
TANK BREATHER VALVE.......................................................................................................................576
FUEL RECEIVER.............................................................................................................................575
FAN DRIVE CLUTCH (M06001).....................................................................................................................579
GENERAL DESCRIPTION.......................................................................................................................579
MAINENANCE................................................................................................................................582
TROUBLESHOOTING...........................................................................................................................584
FIELD CHECK DIAGNOSIS.....................................................................................................................585
THERMAL SENSOR AND SOLENOID VALVE.....................................................................................................586
TROUBLESHOOTING CHART.....................................................................................................................589
COMPONENTS PARTS LIST.....................................................................................................................592
DISASSEMBLY INSTRUCTIONS..................................................................................................................593
REASSEMBLY OF THE FAN CLUTCH..............................................................................................................600
INSPECTION OF PARTS.......................................................................................................................611
REBUILD TOOLS.............................................................................................................................616
ENGINE COOLANT HEATER (M07001)................................................................................................................617
HEATING ELEMENT...........................................................................................................................617
THERMOSTAT................................................................................................................................618
ENGINE OIL HEATERS (M07003)...................................................................................................................619
TROUBLESHOOTING...........................................................................................................................619
HEATING ELEMENT...........................................................................................................................619
ENGINE COOLANT & OIL HEATERS, 440 VOLT (M07004)...............................................................................................621
TROUBLESHOOTING...........................................................................................................................622
COOLANT HEATER ELEMENT....................................................................................................................623
OIL HEATER ELEMENT........................................................................................................................624
THERMOSTAT................................................................................................................................625
SPECIAL TOOLS (M08008)........................................................................................................................627
AIR CONDITIONING SYSTEM (M09003)..............................................................................................................633
PRINCIPLES OF REFRIGERATION...............................................................................................................634
Refrigeration - The Act Of Cooling....................................................................................................634
The Refrigeration Cycle...............................................................................................................635
AIR CONDITIONER SYSTEM COMPONENTS.........................................................................................................635
Compressor (Refrigerant Pump).........................................................................................................635
Service Valves........................................................................................................................635
Condenser.............................................................................................................................635
Filter Receiver-drier.................................................................................................................636
Fusible Pressure Relief Plug..........................................................................................................636
Thermostatic Expansion Valve..........................................................................................................636
Evaporator............................................................................................................................636
Superheat.............................................................................................................................637
SYSTEM SERVICING..........................................................................................................................639
R-12 Containers.......................................................................................................................639
TROUBLESHOOTING...........................................................................................................................656
PRE-DIAGNOSIS CHECKS..................................................................................................................656
PREPARING FOR DIAGNOSIS...............................................................................................................656
PRELIMINARY STEPS.....................................................................................................................656
DIAGNOSIS OF GAUGE READINGS & SYSTEM PERFORMANCE......................................................................................656
TROUBLESHOOTING CHART.....................................................................................................................657
HEATER/AIR CONDITIONER SERVICE................................................................................................................661
COMPONENT SERVICE.........................................................................................................................661
Refrigerant Discharge.................................................................................................................661
COMPRESSOR................................................................................................................................662
Cylinder Head (Gasket) Removal........................................................................................................662
Installation..........................................................................................................................662
Compressor Removal....................................................................................................................662
Installation..........................................................................................................................662
CONDENSER.................................................................................................................................662
Removal...............................................................................................................................663
Installation..........................................................................................................................663
RECEIVER/DRYER............................................................................................................................663
Removal...............................................................................................................................663
Installation..........................................................................................................................663
EVAPORATOR COIL, THERMOSTAT SWITCH, AND EXPANSION VALVE...................................................................................663
EXPANSION VALVE...........................................................................................................................664
Removal...............................................................................................................................664
Installation..........................................................................................................................665
BLOWER MOTOR ASSEMBLY.....................................................................................................................665
Removal...............................................................................................................................666
Installation..........................................................................................................................667
Blower Disassembly....................................................................................................................667
Blower Assembly.......................................................................................................................667
AFTERCOOLER OPERATION AND REPAIR..............................................................................................................669
OPERATION.................................................................................................................................669
MAINTENANCE...............................................................................................................................669
Removal...............................................................................................................................669
Installation..........................................................................................................................669
Disassembly...........................................................................................................................670
Cleaning and Inspection...............................................................................................................671
Assembly..............................................................................................................................671
AIR DRYER (AEROFINER III) (M10003)............................................................................................................673
AIR DRYER.................................................................................................................................673
Service...............................................................................................................................673
Indications To Change Desiccant.......................................................................................................673
Removal...............................................................................................................................674
Installation..........................................................................................................................674
Disassembly...........................................................................................................................674
Assembly..............................................................................................................................675
CHECK VALVE...............................................................................................................................675
Removal...............................................................................................................................675
Installation..........................................................................................................................675
PURGE VALVE & HEATER......................................................................................................................676
Removal...............................................................................................................................676
Inspection............................................................................................................................676
Installation..........................................................................................................................676
SALEM AFTERCOOLER (AIR DRYER) (M10004)........................................................................................................677
AFTERCOOLER/AIR DRYER.....................................................................................................................677
Removal...............................................................................................................................677
Disassembly...........................................................................................................................677
Cleaning and Inspection...............................................................................................................677
Reassembly and Installation...........................................................................................................677
OPTIONAL OPERATOR SEAT (M14001)...............................................................................................................679
SEAT......................................................................................................................................679
Removal...............................................................................................................................679
Installation..........................................................................................................................679
Disassembly...........................................................................................................................680
Assembly..............................................................................................................................682
Air Suspension Cam Adjustment.........................................................................................................683
SEAT MAINTENANCE AND REPAIR...............................................................................................................684
Headrest..............................................................................................................................684
Backrest..............................................................................................................................684
Armrests..............................................................................................................................684
Seat Cushion..........................................................................................................................684
Seat Frame............................................................................................................................684
Slides................................................................................................................................685
Suspension............................................................................................................................685
TDI SINGLE STAGE AIR STARTER (M15001).........................................................................................................689
Disassebly................................................................................................................................689
PARTS INSPECTION (Refer to Figure 15-2 for reference to parts)............................................................................694
Assembly..............................................................................................................................696
TDI TWO-STAGE AIR STARTER.................................................................................................................703
AIR STARTER...........................................................................................................................703
Removal...........................................................................................................................703
Installation......................................................................................................................703
Description of Basic Groups.......................................................................................................703
Disassembly.......................................................................................................................706
Cleaning and Inspection...........................................................................................................708
Assembly..........................................................................................................................710
STARTER...................................................................................................................................689
Removal...............................................................................................................................689
Installation..........................................................................................................................689
Disassembly...........................................................................................................................689
Cleaning..............................................................................................................................693
Parts Inspection......................................................................................................................693
AUTOMATIC TRIP VALVE......................................................................................................................700
Disassembly...........................................................................................................................700
Reassembly............................................................................................................................700
Operation Check.......................................................................................................................701
TDI TWO-STAGE AIR STARTER TROUBLESHOOTING GUIDE...........................................................................................716
INGERSOLL-RAND TURBINE POWERED STARTER (M15002)...............................................................................................717
MAINTENANCE...............................................................................................................................717
Removal...............................................................................................................................717
Installation..........................................................................................................................717
Disassembly Tips......................................................................................................................717
Disassembly - Housing Exhaust Cover, Motor Assembly, and Motor Housing................................................................720
Disassembly - Drive Housing...........................................................................................................722
Assembly Tips.........................................................................................................................724
Lubrication...........................................................................................................................724
Assembly - Gear Case and Drive Housing................................................................................................725
Assembly - Intermediate Gear Case, Motor Housing, Motor Assembly, and Housing Exhaust Cover...........................................726
TEST AND INSPECTION PROCEDURE.............................................................................................................731
TROUBLESHOOTING CHART.....................................................................................................................732
24 VDC ELECTRIC START SYSTEM (M17001).........................................................................................................735
OPERATION.................................................................................................................................735
CRANKING MOTOR............................................................................................................................735
Removal...............................................................................................................................735
Installation..........................................................................................................................735
CRANKING MOTOR TROUBLESHOOTING............................................................................................................736
Preliminary Inspection................................................................................................................736
No-Load Test..........................................................................................................................736
Interpreting Results of Tests.........................................................................................................736
Disassembly...........................................................................................................................737
Cleaning and Inspection...............................................................................................................737
Armature Servicing....................................................................................................................737
Field Coil Checks.....................................................................................................................738
Field Coil Removal....................................................................................................................738
Solenoid Checks.......................................................................................................................740
Test..................................................................................................................................740
Assembly..............................................................................................................................741
Pinion Clearance......................................................................................................................741
Magnetic Switch...........................................................................................................................742
Removal...............................................................................................................................742
Installation..........................................................................................................................742
Coil Test.............................................................................................................................742
ELECTRIC START SYSTEM WIRING DIAGRAMS.....................................................................................................743
HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS) (M20001C1)...........................................................................................747
TROUBLESHOOTING THE HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS)..............................................................................759
ERROR CODES...........................................................................................................................759
GENERAL INFORMATION.......................................................................................................................747
TIPS FOR OPERATION........................................................................................................................747
DECK MOUNTED LIGHTS.......................................................................................................................748
OPERATION AND FUNCTIONS...................................................................................................................748
DISPLAY LOGIC.............................................................................................................................748
METRIC/SHORT TON SELECTION................................................................................................................748
DATA STORAGE LOGIC........................................................................................................................748
DATA PRINT OUT............................................................................................................................749
CLEAR MEMORY..............................................................................................................................749
SETTING THE TIME OF DAY...................................................................................................................749
CALIBRATING THE PAYLOAD METER.............................................................................................................750
To perform calibration:...............................................................................................................750
DIMMING THE PAYLOAD METER DISPLAY.........................................................................................................750
ERROR CODES...............................................................................................................................750
SERVICING THE PAYLOAD METER...............................................................................................................750
Payload Meter Removal.................................................................................................................750
Payload Meter Installation............................................................................................................750
REPLACING PRINTER PAPER...................................................................................................................750
Replacing Paper.......................................................................................................................751
Troubleshooting Paper Printer.........................................................................................................751
REPLACEMENT OF PRINTER MODULE.............................................................................................................751
Printer Module Removal................................................................................................................751
Printer Module Installation...........................................................................................................752
BATTERY (P/N EC2453)......................................................................................................................753
Removal...............................................................................................................................753
Installation..........................................................................................................................753
PRESSURE SENSOR...........................................................................................................................753
To Perform A Sensor Check:............................................................................................................753
Removal...............................................................................................................................754
Installation..........................................................................................................................754
INCLINOMETER..............................................................................................................................754
Removal...............................................................................................................................754
Installation..........................................................................................................................754
RELAYS AND DATA STORAGE TRIGGER MODULE (DSTM).............................................................................................755
PAYLOAD METER SELF TEST FUNCTIONS.........................................................................................................755
CHECK OUT PROCEDURE.......................................................................................................................756
Deck Mounted Lights...................................................................................................................756
Pressure Sensor Location..............................................................................................................756
Error Codes...........................................................................................................................756
Data storage trigger module...........................................................................................................757
Inclinometer..........................................................................................................................757
Body Up Switch........................................................................................................................757
ON-BOARD WEIGHING SYSTEM SCHEMATIC........................................................................................................758
ON-BOARD WEIGHING SYSTEM EXPANDED MEMORY BOX (M20001C3)...................................................................................763
DOWNLOAD..............................................................................................................................763
ANALYSIS..............................................................................................................................763
Tips For Operation................................................................................................................763
GETTING STARTED.......................................................................................................................764
Installing The Software...........................................................................................................764
INITIAL START UP OF THE EXPANDED MEMORY BOX...........................................................................................764
COMMON PROCEDURES.....................................................................................................................765
DOWNLOAD PROGRAM......................................................................................................................766
Payload Box...........................................................................................................................766
Download from Box.................................................................................................................767
Set Date and Time.................................................................................................................767
Clear Box Data....................................................................................................................768
SPECIAL...............................................................................................................................769
Set Max Loads.....................................................................................................................769
Clear Meter.......................................................................................................................770
Box Info..........................................................................................................................770
Set Truck Number..................................................................................................................771
View Data in Box..................................................................................................................771
Set Comm Port.....................................................................................................................772
HELP..................................................................................................................................772
ANALYSIS PROGRAM......................................................................................................................773
ANALYSIS..........................................................................................................................773
Data Tables.......................................................................................................................774
Graphics..........................................................................................................................774
Print Report......................................................................................................................775
SETUP MENU............................................................................................................................775
PRINTER CHART.....................................................................................................................776
HELP MENU.............................................................................................................................777
PAYLOAD DATA..........................................................................................................................778
SERVICE...............................................................................................................................780
Removal...........................................................................................................................780
Installation......................................................................................................................780
Disassembly.......................................................................................................................780
Battery Replacement...............................................................................................................781
Assembly..........................................................................................................................781
Wire Connections..................................................................................................................781
TROUBLESHOOTING EXPANDED MEMORY BOX...................................................................................................782
DETROIT DIESEL ELECTRONIC ENGINE CONTROLS ABBREVIATIONS.......................................................................................201
DDEC II ELECTRONIC ENGINE CONTROL (M21001)....................................................................................................783
DDEC III ELECTRONIC ENGINE CONTROL (M21002)...................................................................................................789
SECTION N OPERATOR'S CAB INDEX....................................................................................................................795
TRUCK CAB.....................................................................................................................................797
TRUCK CAB.................................................................................................................................797
Removal...............................................................................................................................797
Installation..........................................................................................................................797
DOOR WINDOW SERVICE.......................................................................................................................798
Removal...............................................................................................................................799
Installation..........................................................................................................................799
Disassembly...........................................................................................................................799
Assembly..............................................................................................................................799
CAB DOOR..................................................................................................................................799
Removal...............................................................................................................................799
Installation..........................................................................................................................799
Door Adjustment.......................................................................................................................799
Door Latch............................................................................................................................799
Removal...............................................................................................................................799
Installation..........................................................................................................................800
Disassembly...........................................................................................................................800
Assembly..............................................................................................................................800
WINDSHIELD AND REAR WINDOW SERVICE........................................................................................................801
Removal...............................................................................................................................801
Installation..........................................................................................................................801
CAB COMPONENTS................................................................................................................................803
WINDSHIELD WIPER - AIR OPERATED...........................................................................................................803
Removal...............................................................................................................................803
Installation..........................................................................................................................803
Disassembly...........................................................................................................................803
Cleaning and Inspection...............................................................................................................803
Assembly..............................................................................................................................803
WIPER CONTROL VALVE.......................................................................................................................804
Removal...............................................................................................................................804
Installation..........................................................................................................................804
ELECTRIC WINDSHIELD WIPER.................................................................................................................805
Removal...............................................................................................................................805
Installation..........................................................................................................................805
WINDSHIELD WASHER.........................................................................................................................806
Operation.............................................................................................................................806
Service...............................................................................................................................806
AIR HORN..................................................................................................................................806
OPERATOR COMFORT..............................................................................................................................807
OPERATOR SEAT.............................................................................................................................807
Adjustment............................................................................................................................807
Removal...............................................................................................................................807
Installation..........................................................................................................................807
Disassembly...........................................................................................................................808
Inspection............................................................................................................................808
Assembly..............................................................................................................................808
HEATER....................................................................................................................................810
WATER CONTROL VALVE.......................................................................................................................810
BLOWER AND HEATER CORE....................................................................................................................810
Removal...............................................................................................................................810
Installation..........................................................................................................................811
Disassembly...........................................................................................................................812
Assembly..............................................................................................................................812
HEATER COVER..............................................................................................................................813
Installation..........................................................................................................................813
FILTER....................................................................................................................................813
Service...............................................................................................................................813
OPERATOR CONTROLS.............................................................................................................................815
STEERING COLUMN...........................................................................................................................815
Removal...............................................................................................................................815
Disassembly.......................................................................................................................815
Cleaning and Inspection...........................................................................................................818
Assembly..........................................................................................................................818
Installation..........................................................................................................................815
Cleaning and Inspection...............................................................................................................818
Assembly..............................................................................................................................818
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 PANEL..........................................................................................................................822
INSTRUMENT PANEL......................................................................................................................824
INSTRUMENTS AND INDICATORS............................................................................................................824
(1) KEY SWITCH........................................................................................................................824
(2) ENGINE SHUTDOWN (OPTIONAL)........................................................................................................824
(3) WINDSHIELD WIPER/WASHER SWITCH....................................................................................................824
(4) LIGHT SWITCH......................................................................................................................825
(5) ENGINE STARTING AID (OPTIONAL)....................................................................................................825
(6) LADDER LIGHT SWITCH...............................................................................................................825
(7) MANUAL BACKUP LIGHT SWITCH........................................................................................................825
(8) FOG LIGHTS (OPTIONAL).............................................................................................................825
(9) HIGH-MOUNTED HEADLIGHTS (OPTIONAL)................................................................................................825
(10) PANEL LIGHT DIMMER...............................................................................................................825
(11) WATER TEMPERATURE GAUGE..........................................................................................................825
(12) ENGINE OIL PRESSURE GAUGE........................................................................................................825
(13) AIR PRESSURE GAUGE...............................................................................................................825
(14) SPEEDOMETER......................................................................................................................825
(15) LEFT TURN SIGNAL INDICATOR.......................................................................................................825
(16) HIGH BEAM INDICATOR..............................................................................................................826
(17) RIGHT TURN SIGNAL INDICATOR......................................................................................................826
(18) VOLTMETER........................................................................................................................826
(19) WARNING DECAL....................................................................................................................826
(20) BLANK............................................................................................................................826
(21) TACHOMETER.......................................................................................................................826
CAUTION INDICATOR LIGHTS..............................................................................................................826
(22) DYNAMIC RETARDING................................................................................................................826
(23) BODY UP..........................................................................................................................826
(24) SERVICE BRAKE....................................................................................................................826
(25) PARKING BRAKE....................................................................................................................826
(26) ACCUMULATOR BOOSTER (OPTIONAL)...................................................................................................826
(27) MANUAL BACK UP LIGHT.............................................................................................................826
(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 TRIPPED..........................................................................................................827
(34) PARKING BRAKE CONTROL............................................................................................................827
(35) SECONDARY BRAKE CONTROL..........................................................................................................827
(36) DRY ROAD/SLIPPERY ROAD SWITCH....................................................................................................828
(37) WHEEL BRAKE LOCK.................................................................................................................828
RETARD SPEED CONTROLS (RSC) (38, 39, & 40, FIGURE 5-11)...............................................................................828
(38) RETARD SPEED CONTROL INDICATOR...................................................................................................828
(39) RETARD SPEED CONTROL (RSC) SWITCH................................................................................................828
(40) RSC ADJUST DIAL..................................................................................................................828
(41) OVERRIDE PUSHBUTTON..............................................................................................................829
(42) WARNING DECAL....................................................................................................................829
(43) LOW STEERING PRESSURE............................................................................................................829
(44) LOW ACCUMULATOR PRECHARGE........................................................................................................830
(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 Options..............................................................................831
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 PRESSURE...............................................................................................................831
(54) ENGINE MONITOR SECOND (Used Only With “DDEC II” Electronic- Controlled Engine Option)............................................831
(55) ELECTRIC SYSTEM FAULT............................................................................................................831
(56) MOTOR BLOWER OFF.................................................................................................................831
(57) HIGH MOTOR TEMPERATURE (OPTIONAL)................................................................................................831
(58) BLANK............................................................................................................................832
(59) LAMP TEST and Cummins Centry™ Diagnostic Test Switch (if equipped)...............................................................832
(60) HEATER TEMPERATURE CONTROL LEVER.................................................................................................832
(61) DEFROSTER/HEAT CONTROL LEVER.....................................................................................................832
(62) OUTSIDE/INSIDE AIR CONTROL LEVER.................................................................................................832
(63) AIR CONDITIONER CONTROL (OPTIONAL)...............................................................................................832
(64) FAN CONTROL KNOB.................................................................................................................832
(65) AIR CLEANER SERVICE VACUUM GAUGE.................................................................................................833
(66) FUEL LEVEL GAUGE (OPTIONAL)......................................................................................................833
(67) HOURMETER........................................................................................................................833
(68) OVERSPEED ALARM HORN (OPTIONAL)..................................................................................................833
(69) CIRCUIT BREAKERS.................................................................................................................833
CENTRY™ FUEL SYSTEM DIAGNOSTICS - CUMMINS ENGINE ONLY -...........................................................................................834
DETERMINING "FAULT" CODES.....................................................................................................................834
EXITING THE DIAGNOSTICS MODE..................................................................................................................835
SECTION P LUBRICATION AND SERVICE INDEX...........................................................................................................837
LUBRICATION AND SERVICE.......................................................................................................................839
HYDRAULIC TANK SERVICE....................................................................................................................839
Adding Oil............................................................................................................................839
LUBRICATION CHART.........................................................................................................................840
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS........................................................................................841
50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................................843
100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................844
250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................845
500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................846
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................................................................................847
5000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................................................................................848
10000 HOURS LUBRICATION AND MAINTENANCE CHECKS............................................................................................848
MOTORIZED WHEEL MAINTENANCE SCHEDULE..........................................................................................................849
SECTION Q ALPHABETICAL INDEX......................................................................................................................853
SECTION R SYSTEM SCHEMATICS INDEX.................................................................................................................857
AIR SYSTEM SCHEMATIC HA195....................................................................................................................859
AIR SYSTEM SCHEMATIC HA198....................................................................................................................860
BRAKE SYSTEM HYDRAULIC SCHEMATIC HH313........................................................................................................861
HYDRAULIC SYSTEM SCHEMATIC HUSCO VALVE HH309..................................................................................................862
Sheet 1...................................................................................................................................862
Sheet 2...................................................................................................................................863
Sheet 3...................................................................................................................................864
RETARD CONTROL PANEL FOR STATEX III HE378....................................................................................................865
ACCEL INTERFACE PANEL FOR STATEX III HE379..................................................................................................866
STATEX III POWER AND EXCITATION SCHEMATIC HE376...............................................................................................867
Sheet 1...................................................................................................................................867
Sheet 2...................................................................................................................................868
Sheet 3...................................................................................................................................869
ELECTRICAL SCHEMATIC HE400....................................................................................................................870
Sheet 1...................................................................................................................................870
Sheet 2...................................................................................................................................871
Sheet 3...................................................................................................................................872
Sheet 4...................................................................................................................................873
Sheet 5...................................................................................................................................874
Sheet 6...................................................................................................................................875
Sheet 7...................................................................................................................................876
Sheet 8...................................................................................................................................877
Sheet 9...................................................................................................................................878
Sheet 10..................................................................................................................................879
Sheet 11..................................................................................................................................880
Sheet 12..................................................................................................................................881
Sheet 13..................................................................................................................................882
Sheet 14..................................................................................................................................883
Sheet 15..................................................................................................................................884
KOMATSU 630E DUMP TRUCK SHOP MANUAL SN AFE42-M, AFE46-U AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 630E 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 æ10% 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. 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.
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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Colter Raiden –
fast Easy service
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Kenzo Lincoln –
Great Fast Clean manual.