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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL SN A30310, A30312 – A30426 – PDF Download
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- KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL
- Serial Number:A30310, A30312 – A30426
- Publication Number:CEBM014801
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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL SN A30310, A30312 – A30426
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL SN A30310, A30312 – A30426 – PDF DOWNLOAD:
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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL SN A30310, A30312 – A30426
- This manual is written for use by the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing 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 component has a section in the shop manual. Disassembly of any component should only be done 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 in metric units and in U.S. English units. 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 for common fasteners are shown in torque charts in the general information section.
- Special torque requirtements are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating. The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E).
- The three numbers represent the basic truck model. The letter E, when present, designates an electrical wheel motor drive 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.
- The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload. To determine allowable payload, fill all lubricants and fuel tank to the proper level. Weigh the truck and record this value. Subtract it from the GVW to determine the allowable payload
TABLE OF CONTENTS:
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL SN A30310, A30312 – A30426
MAIN MENU........................................................................................... 0 COVER............................................................................................... 1 FOREWORD............................................................................................ 5 TABLE OF CONTENTS................................................................................... 7 SECTION A - GENERAL INFORMATION - INDEX............................................................. 9 SECTION A2 - MAJOR COMPONENT DESCRIPTION........................................................ 11 SECTION A3 - GENERAL SAFETY AND OPERATION - INDEX............................................... 15 GENERAL SAFETY AND OPERATION................................................................ 17 PERSONAL SAFETY......................................................................... 17 Safety Rules........................................................................ 17 Truck Safety Features............................................................... 17 Clothing And Personal Items......................................................... 17 Unauthorized Modification........................................................... 17 Leaving The Operator’s Seat......................................................... 17 Mounting And Dismounting............................................................ 18 Fire Extinguishers And First Aid Kits............................................... 18 Precautions For High Temperature Fluids............................................. 18 Asbestos Dust Hazard Prevention..................................................... 19 Fire Prevention For Fuel And Oil.................................................... 19 ROPS Precautions.................................................................... 19 Preventing Injury From Work Equipment............................................... 19 Precautions For Optional Attachments................................................ 19 Precautions When Starting The Machine............................................... 20 PRECAUTIONS FOR TRUCK OPERATION......................................................... 20 Safety Is Thinking Ahead............................................................ 20 Safety At The Work Site............................................................. 20 Fire Prevention..................................................................... 20 Preparing For Operation............................................................. 20 Ventilation For Enclosed Areas...................................................... 20 Mirrors, Windows, And Lights........................................................ 21 In The Operator’s Cab - Before Starting The Engine.................................. 21 OPERATING THE MACHINE................................................................... 21 Starting The Engine................................................................. 21 Truck Operation - General........................................................... 21 Traveling In The Truck.............................................................. 22 Precautions When Traveling In Reverse............................................... 22 Traveling On Slopes................................................................. 22 Ensuring Good Visibility............................................................ 23 Operating On Snow................................................................... 23 Avoid Damage To The Dump Body....................................................... 23 Driving Near High-Voltage Cables.................................................... 23 When Loading The Truck.............................................................. 23 When Dumping........................................................................ 23 Working On Loose Ground............................................................. 24 Parking The Machine................................................................. 24 TOWING.................................................................................. 24 WORKING NEAR BATTERIES.................................................................. 24 Battery Hazard Prevention........................................................... 24 Jump-Starting With Booster Cables................................................... 25 PRECAUTIONS FOR MAINTENANCE................................................................. 26 BEFORE PERFORMING MAINTENANCE........................................................... 26 Stopping The Engine Before Service.................................................. 26 Warning Tag......................................................................... 26 Proper Tools........................................................................ 26 Securing The Dump Body.............................................................. 26 DURING MAINTENANCE...................................................................... 27 Personnel........................................................................... 27 Attachments......................................................................... 27 Working Under The Machine........................................................... 27 Keeping The Machine Clean........................................................... 27 Rules To Follow When Adding Fuel Or Oil............................................. 27 Radiator Coolant Level.............................................................. 27 Use Of Lighting..................................................................... 28 Precautions With The Battery........................................................ 28 Handling High-Pressure Hoses........................................................ 28 Precautions With High-Pressure Oil.................................................. 28 Maintenance Near High Temperatures And High Pressures............................... 28 Rotating Fan And Belts.............................................................. 28 Waste Materials..................................................................... 28 TIRES................................................................................... 29 Handling Tires...................................................................... 29 Tire Maintenance.................................................................... 29 Storing Tires After Removal......................................................... 30 ADDITIONAL JOB SITE RULES................................................................... 31 WHEN REPAIRS ARE NECESSARY.................................................................. 32 OPERATING INSTRUCTIONS...................................................................... 33 PREPARING FOR OPERATION................................................................. 33 SAFETY IS THINKING AHEAD................................................................ 33 WALK-AROUND INSPECTION.................................................................. 33 ENGINE START-UP......................................................................... 37 AFTER ENGINE HAS STARTED................................................................ 38 MACHINE OPERATION SAFETY PRECAUTIONS.................................................... 39 LOADING................................................................................. 39 HAULING................................................................................. 40 PASSING................................................................................. 40 DUMPING................................................................................. 40 To Raise The Dump Body:............................................................. 41 To Lower The Dump Body: (When dumping over a berm or into a crusher):............... 41 To Lower The Dump Body (When dumping on flat ground):............................... 42 TOWING.................................................................................. 42 SAFE PARKING PROCEDURES................................................................. 43 ENGINE SHUTDOWN PROCEDURE............................................................... 43 DELAYED ENGINE SHUTDOWN PROCEDURE....................................................... 43 SUDDEN LOSS OF POWER.................................................................... 44 EMERGENCY STEERING SYSTEM............................................................... 44 Operation........................................................................... 44 Testing............................................................................. 45 SECTION A4 - WARNINGS AND CAUTIONS.............................................................. 47 SECTION A5 - STANDARD TORQUE CHARTS AND CONVERSION TABLES....................................... 55 SECTION A7 - STORAGE AND IDLE MACHINE PREPARATION - INDEX....................................... 61 STORAGE AND IDLE MACHINE PREPARATION........................................................ 63 SHORT TERM IDLE PERIODS................................................................. 63 PREPARATION FOR STORAGE................................................................. 64 REMOVAL FROM STORAGE.................................................................... 65 RECONDITIONING AN IDLE VEHICLE.......................................................... 66 ENGINE OPERATION........................................................................ 69 After The Engine Has Started........................................................ 69 ENGINE STORAGE.......................................................................... 70 Temporary Storage (30 Days Or Less)................................................. 70 Extended Storage (More Than 30 Days)................................................ 71 RESTORING AN ENGINE AFTER EXTENDED STORAGE.............................................. 72 ELECTRIC DRIVE TRUCKS................................................................... 73 Storing A Truck That Is Operational................................................. 73 Storing A Truck That Is Not Operational............................................. 74 Storing A Major Component........................................................... 75 Periodic Inspections................................................................ 75 Placing Equipment Into Service After Storage........................................ 75 SECTION B - STRUCTURES - INDEX...................................................................... 77 SECTION B2 - STRUCTURAL COMPONENTS - INDEX...................................................... 79 STRUCTURAL COMPONENTS....................................................................... 81 LADDERS................................................................................. 81 Removal............................................................................. 81 Installation........................................................................ 81 GRILLE AND HOOD......................................................................... 82 Removal............................................................................. 82 Installation........................................................................ 82 RIGHT-HAND DECK......................................................................... 82 Removal............................................................................. 82 Installation........................................................................ 84 CENTER DECK............................................................................. 84 LEFT-HAND DECK.......................................................................... 85 Removal............................................................................. 85 Installation........................................................................ 85 SECTION B3 - DUMP BODY - INDEX.................................................................. 87 DUMP BODY................................................................................... 89 DUMP BODY............................................................................... 89 Removal............................................................................. 89 Installation........................................................................ 90 BODY SLING.............................................................................. 90 BODY PADS............................................................................... 91 Adjustment.......................................................................... 91 BODY GUIDE.............................................................................. 92 BODY POSITION INDICATOR................................................................. 92 HOIST LIMIT SWITCH...................................................................... 92 ROCK EJECTORS........................................................................... 92 Inspection.......................................................................... 92 SECTION B4 - FUEL TANK -INDEX................................................................... 93 FUEL TANK................................................................................... 95 Removal................................................................................. 95 Repair.................................................................................. 95 Cleaning................................................................................ 95 Installation............................................................................ 96 FUEL GAUGE SENDER........................................................................... 97 Removal................................................................................. 97 Installation............................................................................ 97 LOW FUEL SENDER............................................................................. 98 Removal................................................................................. 98 Installation............................................................................ 98 FUEL RECEIVER............................................................................... 99 TANK BREATHER VALVE......................................................................... 100 Removal................................................................................. 100 Installation............................................................................ 100 Disassembly............................................................................. 100 Assembly................................................................................ 100 SECTION C - ENGINE - INDEX.......................................................................... 101 SECTION C2 - POWER MODULE - INDEX............................................................... 103 POWER MODULE................................................................................ 105 GENERAL INFORMATION..................................................................... 105 POWER MODULE SERVICE.................................................................... 106 Removal............................................................................. 106 Installation........................................................................ 110 SECTION C3 - COOLING SYSTEM - INDEX............................................................. 113 COOLING SYSTEM.............................................................................. 115 RADIATOR................................................................................ 115 Removal............................................................................. 115 Service............................................................................. 116 Installation........................................................................ 116 RADIATOR FILL PROCEDURE............................................................. 117 RADIATOR REPAIR..................................................................... 117 Internal Inspection............................................................. 117 External Cleaning............................................................... 118 Disassembly..................................................................... 118 Cleaning and Inspection......................................................... 119 Assembly........................................................................ 119 Additional Service Information.................................................. 121 PRESSURE TESTING.................................................................... 121 COOLANT SYSTEM TROUBLESHOOTING...................................................... 121 SECTION C4 - POWER TRAIN - INDEX................................................................ 123 POWER TRAIN................................................................................. 125 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE........................................... 125 General Information................................................................. 125 Removal............................................................................. 125 ALTERNATOR INSTALLATION................................................................. 127 Engine/Alternator Mating............................................................ 127 Alternator Measurement.............................................................. 127 Engine End Play Measurement......................................................... 128 Determining Shim Requirements....................................................... 129 Installing Alternator On Engine..................................................... 130 ENGINE.................................................................................. 131 Removal............................................................................. 131 Installation........................................................................ 131 SECTION C5 - AIR CLEANERS - INDEX............................................................... 133 AIR CLEANERS................................................................................ 135 Service Checks.......................................................................... 135 Filter Element Replacement.............................................................. 136 Main Filter Element Cleaning............................................................ 138 Precleaner Section...................................................................... 139 Cleaning Precleaner Tubes............................................................... 139 Air Intake Troubleshooting.............................................................. 140 SECTION C7 - FAN DRIVE CLUTCH - INEX............................................................ 141 FAN DRIVE CLUTCH............................................................................ 143 GENERAL DESCRIPTION..................................................................... 143 COMPONENTS.............................................................................. 143 Input............................................................................... 143 Output.............................................................................. 143 Stationary Components............................................................... 144 OPERATION MODES......................................................................... 145 Fully Engaged....................................................................... 145 Modulated Variable Speed............................................................ 145 Fully Released...................................................................... 146 Remember:........................................................................... 146 Lubricating and Cooling Oil......................................................... 147 MAINTENANCE............................................................................. 148 Maintenance Checks To Be Made....................................................... 148 TROUBLESHOOTING......................................................................... 149 Basic Preliminary Checks............................................................ 149 FIELD CHECK DIAGNOSIS................................................................... 150 Preliminary Checks With Engine Off.................................................. 150 Check Clutch Release................................................................ 150 Check Clutch Lock-up................................................................ 151 Overheating Complaint............................................................... 152 Thermal Sensor and Solenoid Valve................................................... 152 On Truck Test....................................................................... 152 Off Truck Test...................................................................... 153 Test Conditions and Requirements:................................................... 153 Test:............................................................................... 153 TROUBLESHOOTING CHART....................................................................... 154 FAN CLUTCH DISASSEMBLY INSTRUCTIONS......................................................... 157 REASSEMBLY OF THE FAN CLUTCH................................................................ 164 INSPECTION OF PARTS......................................................................... 175 REBUILD TOOLS............................................................................... 178 SECTION D - ELECTRICAL SYSTEM (24 VDC NON-PROPULSION) - INDEX....................................... 181 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX............................................... 183 24VDC ELECTRIC SUPPLY SYSTEM................................................................ 185 ELECTRICAL SYSTEM DESCRIPTION........................................................... 185 BATTERIES............................................................................... 185 Maintenance and Service............................................................. 185 Troubleshooting..................................................................... 185 BATTERY CHARGING ALTERNATOR............................................................. 187 24VDC ELECTRIC START SYSTEM............................................................. 187 CRANKING MOTORS..................................................................... 187 Removal......................................................................... 187 Installation.................................................................... 188 CRANKING MOTOR TROUBLESHOOTING...................................................... 188 Preliminary Inspection.......................................................... 189 No-Load Test.................................................................... 189 Interpreting Results of Tests................................................... 189 Disassembly..................................................................... 190 Cleaning and Inspection......................................................... 190 Armature Servicing.............................................................. 190 Field Coil Checks............................................................... 193 Field Coil Removal.............................................................. 193 Solenoid Checks................................................................. 193 Test............................................................................ 193 Assembly........................................................................ 194 Pinion Clearance................................................................ 195 MAGNETIC SWITCH..................................................................... 196 Coil Test....................................................................... 196 Electric Start System Wiring Diagrams........................................... 196 ENGINE PRELUB SYSTEM.................................................................... 196 OPERATION........................................................................... 196 Pressure Switch................................................................. 197 Suction Line.................................................................... 197 Outlet Line..................................................................... 197 Check Valve..................................................................... 197 Solenoid Timer.................................................................. 197 TROUBLESHOOTING PRELUB STARTER CIRCUIT...................................................... 199 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX......................................... 203 24VDC ELECTRICAL SYSTEM COMPONENTS.......................................................... 205 PASSENGER SEAT BASE COMPARTMENT......................................................... 205 COMPONENTS.............................................................................. 205 Taillight Resistor Diode Assemblies................................................. 205 Inclinometer........................................................................ 205 Brake Warning Buzzer (BWB).......................................................... 205 Lubrication System Timer............................................................ 205 Five Minute Idle Timer Components................................................... 205 Five Minute Idle Timer.............................................................. 207 Five Minute Idle Relay.............................................................. 207 Five Minute Idle Contactor.......................................................... 207 Five Minute Idle Circuit Test....................................................... 207 Data Store Switch................................................................... 207 Komatsu Engine Quantum Connector (Not Used)......................................... 207 Komatsu Engine Cense Connector...................................................... 207 STATEX III Propulsion System Diagnostic Connector................................... 207 Spare Connector Location............................................................ 207 Alarm Indicating Device (AID) System................................................ 208 Diode Matrix (Without Sound)........................................................ 208 Diode Matrix (With Sound)........................................................... 209 Hot Switch Inverter................................................................. 209 Hot Switch Inverter Card (Slot 4) (Not Used)........................................ 209 Temperature......................................................................... 209 Oil Level........................................................................... 209 Temperature and Latch............................................................... 209 Coolant Level/Flasher............................................................... 210 Lamp Test........................................................................... 210 BATTERY EQUALIZER BOX................................................................... 210 Troubleshooting..................................................................... 210 BODY-UP SWITCH.......................................................................... 211 Adjustment.......................................................................... 211 Service............................................................................. 211 HOIST LIMIT SWITCH...................................................................... 212 Adjustment.......................................................................... 212 Service............................................................................. 212 24-VOLT RELAY AND DIODE BOARDS.......................................................... 212 RELAY BOARDS............................................................................ 213 Description......................................................................... 213 SERVICE................................................................................. 213 To Replace A Relay:................................................................. 213 To Replace A Circuit Breaker:....................................................... 213 To Replace A Circuit Panel Card..................................................... 214 Relay Board Components.............................................................. 214 Installing Additional Circuits...................................................... 215 DIODE BOARD 1....................................................................... 216 Diode Testing....................................................................... 216 CIRCUIT BREAKERS........................................................................ 218 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX............................................... 219 BATTERY CHARGING SYSTEM..................................................................... 223 BATTERY CHARGING SYSTEM................................................................. 223 ELECTRICAL SYSTEM DESCRIPTION....................................................... 223 CHARGE VOLT AND AMP VALUES.......................................................... 223 BATTERY............................................................................. 223 Maintenance and Service......................................................... 223 Troubleshooting................................................................. 224 Undercharging................................................................... 224 Overcharging.................................................................... 224 Corrosion....................................................................... 224 Acid Levels..................................................................... 224 Non-Use or Storage.............................................................. 224 Freezing........................................................................ 225 BATTERY CHARGING ALTERNATOR............................................................. 226 GENERAL INFORMATION................................................................. 226 General Description............................................................. 226 Terminal Identification and Location............................................ 227 Battery Positive (B+)........................................................... 227 Battery Negative (B-)........................................................... 227 DC Output (D+).................................................................. 227 AC Output (R)................................................................... 227 Regulator Harness Plug Identification........................................... 227 Alternator Specifications....................................................... 227 Performance Curve............................................................... 227 Battery/Alternator Terminology.................................................. 228 WIRING DIAGRAM...................................................................... 230 DIMENSIONS AND TORQUE VALUES........................................................ 231 PERIODIC MAINTENANCE................................................................ 232 TESTING................................................................................. 232 GENERAL INFORMATION................................................................. 232 Troubleshooting Alternator (On-Truck)........................................... 232 Equipment Required.............................................................. 232 Preliminary Checks.............................................................. 232 Test Set-up..................................................................... 234 Test Procedure.................................................................. 235 REGULATOR TESTING................................................................... 236 Regulator Bypass Test (No Output)............................................... 236 Regulator Bypass Test (Amp Rating).............................................. 237 BENCH TESTING....................................................................... 238 Equipment....................................................................... 238 Identification Record........................................................... 238 Advanced Troubleshooting........................................................ 238 Bench Test 1: No-Load Test...................................................... 238 Bench Test 2: Full Load Test.................................................... 239 Bench Test 3: Regulator Bypass Test............................................. 239 STATIC TESTING...................................................................... 240 Equipment....................................................................... 240 Identification Record........................................................... 240 Regulator Tester................................................................ 240 Check For Shorted Power Transistor.............................................. 240 Circuit Tests................................................................... 241 FIELD COIL TESTS.................................................................... 242 Field Coil Test 1: Check for Open or Shorted Field Coil......................... 242 Field Coil Test 2: Check For Grounded Field Coil................................ 242 STATOR TESTS........................................................................ 243 Stator Test 1: Check For Stator-To-Stator Continuity............................ 243 Stator Test 2: Check For Grounded Stators....................................... 244 THERMAL SWITCH TEST................................................................. 244 Initial Test.................................................................... 244 Verifying a Faulty Thermal Switch............................................... 245 TROUBLESHOOTING TIPS................................................................ 246 ALTERNATOR.............................................................................. 250 ALTERNATOR REPAIR................................................................... 250 Removal......................................................................... 250 Installation.................................................................... 252 Special Tools and Lubricants.................................................... 252 Epoxy Adhesive.................................................................. 253 Liquid Threadlockers............................................................ 253 Elastoplastic Silicone Resin.................................................... 253 ALTERNATOR EXPLODED VIEW............................................................ 256 ALTERNATOR DISASSEMBLY.............................................................. 258 Regulator Removal............................................................... 258 Fan Removal..................................................................... 259 Pulley Removal.................................................................. 260 Anti-Drive End Housing Removal.................................................. 260 Anti-Drive End Rotor Removal.................................................... 262 Drive End Housing Removal....................................................... 264 Drive End Rotor Removal......................................................... 270 Field Coil Removal.............................................................. 271 Drive End and/or Anti-Drive End Stator Removal.................................. 273 CLEANING AND INSPECTION............................................................. 275 ALTERNATOR ASSEMBLY................................................................. 275 Anti-Drive End Stator Installation.............................................. 275 Drive End Stator Installation................................................... 277 Field Coil Installation......................................................... 280 Drive End Bearing Installation.................................................. 282 Drive End Rotor Installation.................................................... 284 Rotor and Rotor Shaft Installation.............................................. 284 Drive End Housing Installation.................................................. 285 Anti-Drive End Rotor Installation............................................... 289 Anti-Drive End Housing Installation............................................. 290 Regulator Installation.......................................................... 293 THERMAL SWITCH...................................................................... 294 Removal......................................................................... 294 Installation.................................................................... 296 SUPPORT STAND....................................................................... 296 SECTION D35 - PAYLOAD METER III - INDEX......................................................... 297 OPERATION SECTION........................................................................... 303 Introduction............................................................................ 303 Data Summary........................................................................ 303 Data Gathering...................................................................... 303 COMPONENT DESCRIPTION................................................................... 304 System Diagram...................................................................... 304 Suspension Pressure Sensors......................................................... 304 Inclinometer........................................................................ 304 Operator Display.................................................................... 304 Operator Switch..................................................................... 305 Speed Input......................................................................... 305 Body-Up Switch...................................................................... 305 Brake Lock Switch................................................................... 305 Payload Meter....................................................................... 305 Communications Ports................................................................ 305 Key Switch Input.................................................................... 306 Payload Meter Power................................................................. 306 Load Lights......................................................................... 306 Wiring and Termination.............................................................. 307 TCI Outputs......................................................................... 307 OPERATOR’S DISPLAY AND SWITCH........................................................... 308 Reading the Speedometer............................................................. 308 Reading the Load Display............................................................ 308 Using the Operator ID............................................................... 308 Using the Load and Ton Counter...................................................... 308 Total Ton Counter................................................................... 308 Total Load Counter.................................................................. 309 Clearing the Counters............................................................... 309 Viewing Live Sensor Data............................................................ 309 Other Display Messages.............................................................. 309 PAYLOAD OPERATION AND CALCULATION....................................................... 310 Description of Haul Cycle States.................................................... 310 Haul Cycle Description.............................................................. 310 Load Calculation.................................................................... 311 Carry Back.......................................................................... 311 Measurement Accuracy................................................................ 311 SOURCES FOR PAYLOAD ERROR............................................................... 311 Payload Error....................................................................... 311 Loading Conditions.................................................................. 312 Pressure Sensors.................................................................... 312 Swingloads.......................................................................... 312 Speed and Distance.................................................................. 312 HAUL CYCLE DATA......................................................................... 312 Haul Cycle Data..................................................................... 313 Haul Cycle Warning Flags............................................................ 314 Frame Torque Data................................................................... 315 Sprung Weight Data.................................................................. 315 Maximum Speed Data.................................................................. 315 Alarm Records....................................................................... 315 Fault Code Data..................................................................... 316 PC SOFTWARE OVERVIEW.................................................................... 317 PC Overview......................................................................... 317 System Configuration................................................................ 317 Installing the PLMIII Software...................................................... 317 DOWNLOADING DATA........................................................................ 318 PLM III SYSTEM CONFIGURATION............................................................ 319 Starting Communications............................................................. 319 Displayed Payload Units............................................................. 319 Time Units.......................................................................... 319 Connection Menu..................................................................... 319 Connecting to the Payload Meter..................................................... 320 Configure the Payload Meter......................................................... 320 Setting the Date and Time........................................................... 320 Setting the Truck Type.............................................................. 321 Setting the Gauge Display Units..................................................... 321 Setting the Frame Serial Number..................................................... 321 Setting the Truck Number............................................................ 321 Setting the Komatsu Distributor..................................................... 321 Setting the Komatsu Customer........................................................ 321 Clean Truck Tare.................................................................... 322 Inclinometer Calibration............................................................ 322 DATA ANALYSIS........................................................................... 323 Creating a Query.................................................................... 323 Sorting on Truck Unit Number........................................................ 323 Sorting on Truck Type............................................................... 323 Sorting on Date Range............................................................... 324 Sorting on Time Range............................................................... 324 Payload Detail Screen............................................................... 325 Creating Reports.................................................................... 325 Summary - One Page Report........................................................... 326 Detailed - Multi-Page Report........................................................ 326 Creating Graphs..................................................................... 327 Exporting Data...................................................................... 327 CSV Export.......................................................................... 327 Compressed.......................................................................... 329 Importing Data...................................................................... 329 Deleting Haul Cycle Records......................................................... 329 Viewing Alarms...................................................................... 330 Deleting Alarm Records.............................................................. 330 TROUBLESHOOTING SECTION..................................................................... 331 TROUBLESHOOTING......................................................................... 331 Viewing Active Alarms............................................................... 331 Real-Time Data Display.............................................................. 331 Testing the Payload Lights.......................................................... 332 Creating Log Files of Inputs........................................................ 332 Daily Inspections................................................................... 332 Periodic Maintenance................................................................ 332 Abnormal Displays at Power-Up....................................................... 333 No Payload Display When Key Switch is Turned On..................................... 334 No Display on Speedometer........................................................... 335 No Display on Operator Display...................................................... 335 No Communications With PC........................................................... 336 Load Lights Don’t Light During Loading.............................................. 337 Load Lights Remain On............................................................... 338 Load Lights Remain On During Dumping................................................ 338 Display Doesn't Clear When The Load Is Dumped....................................... 338 Calibration Problems................................................................ 339 Alarm 1 - Left-Front Pressure High.................................................. 340 Alarm 2 - Left-Front Pressure Low................................................... 340 Troubleshoot Wiring to Left-Front Suspension........................................ 340 Alarm 3 - Right-Front Pressure High................................................. 341 Alarm 4 - Right-Front Pressure Low.................................................. 341 Troubleshoot Wiring to Right-Front Suspension....................................... 341 Alarm 5 - Left-Rear Pressure High................................................... 342 Alarm 6 - Left-Rear Pressure Low.................................................... 342 Troubleshoot Wiring to Left-Rear Suspension......................................... 342 Alarm 7 - Right-Rear Pressure High.................................................. 343 Alarm 8 - Right-Rear Pressure Low................................................... 343 Troubleshoot Wiring to Right-Rear Suspension........................................ 343 Alarm 9 - Inclinometer High......................................................... 344 Alarm 10 - Inclinometer Low......................................................... 344 Troubleshoot Inclinometer Wiring.................................................... 344 Alarm 13 - Body-Up Input Failure.................................................... 345 Alarm 16 - Memory Write Failure..................................................... 346 Alarm 17 - Memory Read Failure...................................................... 346 Alarm 18............................................................................ 347 Alarm 19............................................................................ 347 Alarm 22............................................................................ 347 Operator Switch Doesn't Work........................................................ 348 Alarm 26 - User Switch Fault - SELECT............................................... 348 Alarm 27 - User Switch Fault - SET.................................................. 348 Connector Map....................................................................... 349 Connectors.......................................................................... 350 PLMIII CHECKOUT PROCEDURE................................................................... 351 General Description..................................................................... 351 Tools Required.......................................................................... 351 Checkout Procedure...................................................................... 351 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................. 355 Flashburn Programming............................................................... 355 Confirmation Checklist.............................................................. 357 SECTION E - ELECTRICAL PROPULSION COMPONENTS - INDEX................................................ 359 SECTION E2 - ELECTRICAL PROPULSION COMPONENTS - INDEX........................................... 361 ELECTRICAL PROPULSION COMPONENTS............................................................ 365 GENERAL SYSTEM DESCRIPTION.............................................................. 365 CONTROL SYSTEM.......................................................................... 365 System Operation.................................................................... 366 FL275 Panel......................................................................... 367 CARD REPLACEMENT........................................................................ 368 Removal............................................................................. 368 Installation........................................................................ 368 Card Repair......................................................................... 368 Panel Wiring........................................................................ 368 COMPUTER DESCRIPTION.................................................................... 369 Microprocessor...................................................................... 369 Download Capability................................................................. 369 SOFTWARE................................................................................ 369 Base Monitor Program................................................................ 369 Runtime Monitor Program - OBJ Running Code.......................................... 369 Configuration Software - CFG........................................................ 370 PTU - Portable Test Unit Code....................................................... 370 System Regulation................................................................... 370 Propulsion.......................................................................... 371 Retarding........................................................................... 371 TWO-DIGIT DISPLAY PANEL................................................................. 372 The Coded Number.................................................................... 372 Events.............................................................................. 372 Frames.............................................................................. 373 Windows............................................................................. 373 System Categories................................................................... 373 Limits On Resetting Faults.......................................................... 373 NA Faults........................................................................... 374 Event Sequence...................................................................... 374 Resetting Events.................................................................... 374 Event Descriptions.................................................................. 374 Subcode Descriptions................................................................ 374 2-DIGIT DISPLAY PANEL SUBCODES.......................................................... 382 PORTABLE TEST UNIT (PTU).................................................................... 385 DESCRIPTION............................................................................. 385 Operational Hints................................................................... 385 SOFTWARE INSTALLATION PREPARATION....................................................... 386 HARD DISK SPACE REQUIREMENTS............................................................ 386 SOFTWARE INSTALLATION ON PTU............................................................ 386 PTU/Truck Communication Problems.................................................... 387 THE MAIN MENU........................................................................... 388 Quit Menu........................................................................... 388 PTU Talk To Truck................................................................... 388 View PTU Saved Files................................................................ 388 List Stat Data Files................................................................ 388 Truck Setup (CFG)................................................................... 388 Select Truck Setup.................................................................. 388 Update CFG Version.................................................................. 388 Change PTU Password................................................................. 388 CONFIGURATION (CFG) FILE CONVERSION..................................................... 390 Conversion Procedure................................................................ 390 Convert Old CFG files for New software.............................................. 391 STATEX CONFIGURATION FILES.............................................................. 394 0) Source Directory: . . ........................................................... 394 1) Select A Truck Configuration . . ................................................ 395 2) View Truck Configuration: Data Curves . . ....................................... 396 3) Change/View Serial and Model Numbers . . ........................................ 397 4) View Options . . ................................................................ 397 5) Change/View Truck Specifics . . ................................................. 399 6) Change/View Overspeeds . . ...................................................... 401 7) Save a Truck Configuration, filename: . . ....................................... 402 8) Save Directory: . . ............................................................. 403 CHANGE PTU PASSWORD..................................................................... 404 PROGRAMMING THE TRUCK................................................................... 405 Connect PTU to the Truck............................................................ 405 Select Configuration File........................................................... 405 Activate The PTU Mode............................................................... 405 Check Object Code Version........................................................... 406 Download Configuration Files........................................................ 407 Date And Time....................................................................... 408 Event Data.......................................................................... 409 Statistical Data.................................................................... 411 View Counters....................................................................... 411 View Profiles....................................................................... 411 Upload Statistical Data To A File................................................... 411 Statistical Data Codes - Counters................................................... 412 STATISTICAL DATA CODES - COUNTERS....................................................... 413 STATISTICAL DATA CODES - PROFILES....................................................... 418 TRUCK SPECIFIC INFORMATION.............................................................. 422 Temporary Truck Settings............................................................ 423 MISCELLANEOUS FEATURES.................................................................. 424 Saving Data......................................................................... 424 PTU Abbreviations................................................................... 425 Other Menu Selections............................................................... 425 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS.............................................. 426 ALTERNATOR.............................................................................. 426 ELECTRIC WHEEL MOTORS................................................................... 426 RETARDING GRIDS......................................................................... 426 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 426 Removal............................................................................. 426 Installation........................................................................ 426 Disassembly......................................................................... 427 Reassembly.......................................................................... 427 COOLING BLOWER WARNING SYSTEM........................................................... 427 Operation........................................................................... 427 Test................................................................................ 427 Removal............................................................................. 428 Installation........................................................................ 428 ELECTRICAL CONTROL CABINET.................................................................. 429 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS...................................... 434 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III.......................................... 435 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE............................................. 437 SECTION E3 - STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE - INDEX ........................... 437 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE............................................. 441 GENERAL INFORMATION..................................................................... 441 COMMUNICATIONS PORT CHECK............................................................... 442 PTU Hookup.......................................................................... 442 4.0 SEQUENCE TESTS - (ENGINE NOT ON).................................................... 443 Preparation and Setup............................................................... 443 CONTROL SYSTEM SELF-TEST............................................................ 444 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT............................................ 444 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT.............................................. 445 PTU Setup....................................................................... 445 4.3 REVERSER AND PROPULSION CONTACTORS CHECK........................................ 446 4.4 NOT USED........................................................................ 447 4.5 RETARD CONTACTORS OPERATION CHECK............................................... 447 4.6 GROUND FAULT SENSING CHECK...................................................... 447 4.7 GROUND FAULT IN RETARD OPERATION CHECK.......................................... 448 4.8 OVERRIDE OPERATION CHECK........................................................ 448 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK............................................... 449 4.10 OVERSPEED RETARD OPERATION CHECK............................................... 449 4.11 HOIST INTERLOCK OPERATION CHECK................................................ 450 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK....................................... 450 Return to Main Menu............................................................. 450 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL................................ 451 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU................................... 451 5.2 DIGITAL INPUT CHECKS............................................................ 452 5.3 DIGITAL OUTPUT CHECKS........................................................... 453 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL........................................ 457 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU........................................ 457 6.2 ANALOG INPUT CHECKS............................................................. 458 6.3 FREQUENCY INPUT CHECKS.......................................................... 462 Return to Main Menu............................................................. 463 7.0 SPEED EVENT CHECKS.................................................................. 463 Preparation and Setup............................................................... 463 Setup PTU........................................................................... 463 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK......................... 464 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK.............. 464 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK............. 464 7.4 OTHER SPEED EVENTS CHECKS....................................................... 464 Return to Main Menu............................................................. 464 8.0 RETARD SPEED CONTROL SYSTEM CHECK................................................... 465 Preparation and Setup............................................................... 465 Setup PTU........................................................................... 465 8.1 OVERSPEED PICKUP AND DROPOUT CHECK.............................................. 465 8.2 RETARD POT MAXIMUM SETTING CHECK................................................ 465 8.3 RETARD POT MINIMUM SETTING CHECK................................................ 465 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL.............................. 466 Return to Main Menu............................................................. 466 9.0 LOAD TEST USING TRUCK RETARD GRIDS.................................................. 466 Setup and Preparation............................................................... 466 PTU Setup........................................................................... 466 9.1 LOAD TEST....................................................................... 467 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING............................................. 467 Setup PTU........................................................................... 467 10.1 RETARD CHECK................................................................... 468 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT........................................ 469 11.1 BRAKE SYSTEM INTERLOCKS CHECK.................................................. 469 Preparation..................................................................... 469 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT......................................... 469 11.3 SYNC TRANSFORMER CHECKOUT...................................................... 470 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT..................................... 470 11.5 BATTERY BOOST ADJUSTMENT....................................................... 470 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST.................................... 470 11.7 MOTOR ROTATION TEST............................................................ 471 11.8 GROUND FAULT CHECKS............................................................ 471 12.0 MISCELLANEOUS CHARTS............................................................... 472 12.1 WHEEL MOTOR GEAR RATIOS........................................................ 472 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS................................................. 473 12.3 ENGINE OPTIONS................................................................. 474 SECTION G - DRIVE AXLE, SPINDLE, AND WHEELS - INDEX................................................. 475 SECTION G2 - TIRES AND RIMS - INDEX............................................................. 477 TIRES AND RIMS.............................................................................. 479 GENERAL INFORMATION..................................................................... 479 TIRES................................................................................... 479 Handling Tires...................................................................... 479 Tire Maintenance.................................................................... 480 Storing Tires After Removal......................................................... 480 FRONT TIRES AND RIMS.................................................................... 481 Removal............................................................................. 481 Installation........................................................................ 482 REAR TIRES AND RIMS..................................................................... 483 Removal............................................................................. 483 Installation........................................................................ 484 RIM................................................................................. 485 Tire Removal........................................................................ 485 RIM AND TIRE PREPARATION................................................................ 486 LUBRICANTS.............................................................................. 486 TIRE INSTALLATION....................................................................... 487 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX................................................ 489 FRONT WHEEL HUB AND SPINDLE................................................................. 491 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 491 Removal............................................................................. 491 Installation........................................................................ 493 Disassembly......................................................................... 494 Cleaning and Inspection............................................................. 495 Assembly............................................................................ 495 Wheel Bearing Adjustment (Spindle Vertical)......................................... 498 Wheel Bearing Adjustment (Tire Mounted)............................................. 499 STEERING CYLINDERS AND TIE ROD.......................................................... 500 Spherical Bearing Wear Limits....................................................... 500 Removal............................................................................. 501 Installation........................................................................ 503 Bearing Replacement................................................................. 503 TOE-IN ADJUSTMENT....................................................................... 504 SECTION G4 - REAR AXLE HOUSING - INDEX.......................................................... 505 REAR AXLE HOUSING........................................................................... 507 PIVOT PIN............................................................................... 507 Removal............................................................................. 507 Installation........................................................................ 508 PIVOT EYE BEARING....................................................................... 508 Disassembly......................................................................... 508 Assembly............................................................................ 509 PIVOT EYE REPAIR........................................................................ 509 Removal............................................................................. 509 Disassembly......................................................................... 509 Bushing (New)....................................................................... 509 Pivot Eye Bore (New)................................................................ 509 Assembly............................................................................ 509 Installation........................................................................ 510 ANTI-SWAY BAR........................................................................... 510 Removal............................................................................. 510 Installation........................................................................ 510 Disassembly......................................................................... 511 Cleaning and Inspection............................................................. 511 Assembly............................................................................ 511 SECTION G5 - REAR AXLE HOUSING - INDEX.......................................................... 513 REAR AXLE HOUSING........................................................................... 515 REAR AXLE HOUSING....................................................................... 515 Removal............................................................................. 515 Installation........................................................................ 515 WHEEL MOTOR............................................................................. 515 Removal............................................................................. 515 Cleaning and Inspection............................................................. 516 Installation........................................................................ 516 Maximum Cap Screw Usage............................................................. 516 REAR AXLE HOUSING BUMPER PAD............................................................ 517 SECTION H - SUSPENSION - INDEX...................................................................... 519 SECTION H2 - FRONT SUSPENSION - INDEX........................................................... 521 FRONT SUSPENSION............................................................................ 523 Removal................................................................................. 523 Installation............................................................................ 525 Turn-of-the-Nut Tightening Procedure.................................................... 526 Disassembly............................................................................. 527 Cleaning and Inspection................................................................. 528 Assembly (Bearing Only)................................................................. 528 Suspension Assembly (Complete).......................................................... 528 SUSPENSION PRESSURE TEST................................................................ 530 SECTION H3 - REAR SUSPENSIONS - INDEX........................................................... 533 REAR SUSPENSIONS............................................................................ 535 Removal................................................................................. 536 Installation............................................................................ 538 Disassembly............................................................................. 538 Cleaning and Inspection................................................................. 538 Assembly................................................................................ 539 SUSPENSION PRESSURE TEST................................................................ 541 SECTION H4 - OILING AND CHARGING PROCEDURES - INDEX............................................. 543 OILING AND CHARGING PROCEDURE............................................................... 545 GENERAL................................................................................. 545 EQUIPMENT LIST.......................................................................... 545 Hydrair® Charging Kit............................................................... 545 Installation of Charging Kit........................................................ 545 Removal of Charging Kit............................................................. 546 Support Blocks For Oiling and Charging Dimensions................................... 546 FRONT SUSPENSION........................................................................ 547 Front Suspension Oiling............................................................. 547 Front Suspension Nitrogen Charging.................................................. 548 REAR SUSPENSION......................................................................... 550 Rear Suspension Oiling.............................................................. 550 Rear Suspension Nitrogen Charging................................................... 552 OIL AND NITROGEN SPECIFICATIONS CHART....................................................... 553 SECTION J - BRAKE CIRCUIT - INDEX................................................................... 555 SECTION J2 - BRAKE CIRCUIT - INDEX.............................................................. 557 BRAKE CIRCUIT............................................................................... 559 GENERAL DESCRIPTION..................................................................... 559 SERVICE BRAKE CIRCUIT................................................................... 559 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 561 PARKING BRAKE CIRCUIT................................................................... 561 Normal Operation (key switch on, engine on)......................................... 561 BRAKE LOCK CIRCUIT...................................................................... 562 WARNING CIRCUIT......................................................................... 562 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX............................................ 565 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 567 BRAKE VALVE............................................................................. 567 Rebuild Criteria.................................................................... 567 Removal............................................................................. 567 Installation........................................................................ 569 Disassembly......................................................................... 571 Cleaning and Inspection............................................................. 573 ASSEMBLY................................................................................ 573 Actuator Base Threaded Inserts...................................................... 573 Boot and Cap........................................................................ 573 Valve Body Seal Installation........................................................ 574 Regulator Sleeve O-Ring Installation................................................ 575 Actuator Plunger O-Ring Installation................................................ 575 Assembly of Valve................................................................... 575 DIFFERENTIAL PRESSURE SWITCH............................................................ 576 Disassembly......................................................................... 577 Cleaning and Inspection............................................................. 577 Assembly............................................................................ 577 VALVE BENCH TEST AND ADJUSTMENT......................................................... 577 Test Set Up Procedure............................................................... 579 Brake Valve Output Pressure Adjustment.............................................. 579 Differential Pressure Switch Test................................................... 580 Final Test and Adjustment........................................................... 580 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 581 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (DUAL FUNCTION PEDAL).... 583 Installation of Retard Pedal To Brake Pedal......................................... 583 HYDRAULIC BRAKE ACCUMULATORS............................................................ 584 Brake Accumulator Bleed-Down Procedure.............................................. 584 Removal............................................................................. 584 Installation........................................................................ 586 Disassembly......................................................................... 586 Cleaning and Inspection............................................................. 588 Assembly............................................................................ 588 Leak Testing........................................................................ 590 BRAKE ACCUMULATOR CHARGING.............................................................. 591 Temperature During Precharge........................................................ 593 ACCUMULATOR STORAGE..................................................................... 594 Installation........................................................................ 594 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 597 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX.......................................... 597 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 599 EQUIPMENT REQUIRED...................................................................... 602 INITIAL SYSTEM SET-UP................................................................... 603 Parking Brake....................................................................... 603 Service Brakes...................................................................... 604 Brake Lock/Secondary................................................................ 604 Low Brake Pressure and Auto Apply................................................... 605 Reapplications...................................................................... 605 Differential Pressure Switch........................................................ 605 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 607 CHECK-OUT PROCEDURE......................................................................... 610 HYDRAULIC BRAKE SYSTEM DATA SHEET........................................................... 610 SECTION J5 - FRONT DISC BRAKES - INDEX.......................................................... 613 FRONT DISC BRAKES........................................................................... 615 BRAKE CALIPER........................................................................... 615 Removal............................................................................. 615 Installation........................................................................ 616 Disassembly......................................................................... 617 Cleaning and Inspection............................................................. 617 Assembly............................................................................ 619 BRAKE LINING............................................................................ 619 Replacement......................................................................... 619 FRONT SERVICE BRAKE BURNISHING.......................................................... 621 BRAKE BLEEDING PROCEDURE............................................................ 622 REAR DISC BRAKES............................................................................ 625 REAR BRAKES............................................................................. 625 CALIPER, DISC, AND PARKING BRAKE........................................................ 625 Removal............................................................................. 625 Installation........................................................................ 626 Trucks equipped with one-piece adapter.............................................. 629 Removal............................................................................. 629 Installation........................................................................ 630 CALIPER PISTON.......................................................................... 631 Piston Assembly Removal............................................................. 631 Inspection.......................................................................... 631 Piston Assembly Installation........................................................ 632 FUNCTIONAL TEST OF PISTON ASSEMBLY...................................................... 633 Return Spring Force................................................................. 633 Built-In Clearance.................................................................. 633 Grip Force.......................................................................... 634 Grip Force Measurement.............................................................. 636 Spring Force Measurement............................................................ 637 Disassembly of Piston Assembly...................................................... 638 Assembly of Piston Assembly......................................................... 639 BENCH TEST.............................................................................. 639 BRAKE LINING............................................................................ 640 Replacement......................................................................... 640 SERVICE BRAKE BURNISHING................................................................ 643 SAFETY PRECAUTIONS.................................................................. 643 Rear Brake Conditioning......................................................... 644 BRAKE BLEEDING PROCEDURE............................................................ 645 Spring Force Measurement........................................................ 646 SECTION J6 - REAR BRAKES - INDEX................................................................ 623 SECTION J7 - PARKING BRAKE - INDEX.............................................................. 647 PARKING BRAKE............................................................................... 649 GENERAL INFORMATION..................................................................... 649 PARKING BRAKE CALIPER................................................................... 649 Lining Thickness Inspection......................................................... 649 Removal............................................................................. 650 Installation........................................................................ 650 Parking Brake Adjustment............................................................ 651 Parking Brake Caliper Disassembly................................................... 652 Cleaning and Inspection............................................................. 653 Parking Brake Caliper Assembly...................................................... 654 PARKING BRAKE LINING REPLACEMENT........................................................ 654 PARKING BRAKE BURNISH PROCEDURE......................................................... 654 Lining Conditioning................................................................. 654 BRAKE BLEEDING PROCEDURE................................................................ 655 SECTION L - HYDRAULIC SYSTEM - INDEX................................................................ 657 SECTION L2 - HYDRAULIC SYSTEM - INDEX........................................................... 659 HYDRAULIC SYSTEM............................................................................ 661 GENERAL INFORMATION..................................................................... 661 HYDRAULIC SYSTEMS OPERATION............................................................. 661 Hoist Circuit Operation............................................................. 661 Steering Circuit Operation.......................................................... 663 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX.......................................... 667 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 669 HOIST PUMP.............................................................................. 669 Removal............................................................................. 669 Installation........................................................................ 670 Disassembly......................................................................... 671 Inspection of Parts................................................................. 674 Assembly............................................................................ 674 Troubleshooting Guide............................................................... 678 HYDRAULIC TANK.......................................................................... 679 Filling Instructions................................................................ 679 Removal............................................................................. 680 Installation........................................................................ 680 HYDRAULIC TANK STRAINER AND DIFFUSER.................................................... 680 Removal............................................................................. 680 Inspect and Clean................................................................... 681 Installation........................................................................ 681 SECTION L4 - STEERING CIRCUIT - INDEX........................................................... 683 STEERING CIRCUIT............................................................................ 685 STEERING CIRCUIT OPERATION.............................................................. 685 COMPONENT DESCRIPTION................................................................... 686 Steering Control Valve.............................................................. 686 Unloader Valve...................................................................... 687 Bleed-Down Manifold Valve........................................................... 687 Flow Amplifier...................................................................... 693 FLOW AMPLIFIER SYSTEM OPERATION......................................................... 694 No Steer............................................................................ 694 Steering Left....................................................................... 696 Steering Right...................................................................... 698 No Steer, External Shock Load....................................................... 700 Steering Pump....................................................................... 702 High Pressure Filter................................................................ 702 Accumulators........................................................................ 702 Low Precharge Warning Switch........................................................ 702 SECTION L5 - STEERING CONTROL UNIT - INDEX...................................................... 703 STEERING CONTROL UNIT....................................................................... 705 GENERAL INFORMATION..................................................................... 705 Removal............................................................................. 705 Installation........................................................................ 705 STEERING CONTROL UNIT REBUILD........................................................... 707 Disassembly......................................................................... 707 Cleaning and Inspection............................................................. 708 Assembly............................................................................ 710 STEERING/BRAKE PUMP..................................................................... 713 Removal............................................................................. 713 Installation........................................................................ 713 Disassembly......................................................................... 715 Inspection of Parts................................................................. 716 Assembly............................................................................ 716 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX.......................................... 719 STEERING CIRCUIT COMPONENT REPAIR........................................................... 721 BLEED-DOWN MANIFOLD..................................................................... 721 Removal............................................................................. 721 Installation........................................................................ 721 ACCUMULATOR............................................................................. 722 Removal............................................................................. 722 Installation........................................................................ 723 Disassembly......................................................................... 724 Cleaning and Inspection............................................................. 724 Assembly............................................................................ 724 Leak Testing........................................................................ 725 STEERING ACCUMULATOR CHARGING........................................................... 727 Temperature During Precharge........................................................ 730 ACCUMULATOR STORAGE..................................................................... 730 Installation........................................................................ 731 FLOW AMPLIFIER.......................................................................... 732 Removal............................................................................. 732 Installation........................................................................ 732 Disassembly......................................................................... 732 Assembly............................................................................ 735 STEERING CYLINDERS...................................................................... 736 Disassembly......................................................................... 736 Piston Seal and Bearing Installation................................................ 736 Cylinder Assembly................................................................... 736 Test................................................................................ 737 TROUBLESHOOTING CHART....................................................................... 739 SECTION L7 - HOIST CIRCUIT - INDEX.............................................................. 743 HOIST CIRCUIT............................................................................... 745 HOIST CIRCUIT OPERATION................................................................. 745 COMPONENT DESCRIPTION................................................................... 746 Hydraulic Tank...................................................................... 746 Hydraulic Pump...................................................................... 746 High Pressure Filter................................................................ 746 Hoist Valve......................................................................... 746 Hoist Pilot Valve................................................................... 747 Bleed-Down Manifold................................................................. 748 Counterbalance Manifold............................................................. 748 Hoist-Up Limit Solenoid............................................................. 748 Pilot Operated Check Valve.......................................................... 748 HOIST VALVE OPERATION................................................................... 749 Float Operation..................................................................... 749 Power Up Operation (Figure 7-5)..................................................... 751 Hold Operation (Figure 7-6)......................................................... 753 Power Down Operation (Figure 7-7)................................................... 755 Float Operation (Figure 7-8)........................................................ 757 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX............................................. 759 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 761 HOIST VALVE............................................................................. 761 Removal............................................................................. 761 Installation........................................................................ 761 O-Ring Replacement.................................................................. 763 INLET SECTION........................................................................... 764 Disassembly......................................................................... 764 Cleaning and Inspection............................................................. 765 Assembly............................................................................ 765 REAR SPOOL SECTION (WORK PORTS)......................................................... 766 Disassembly......................................................................... 766 Cleaning and Inspection............................................................. 768 Assembly............................................................................ 768 HOIST PILOT VALVE....................................................................... 770 Removal............................................................................. 770 Installation........................................................................ 770 Disassembly......................................................................... 771 Cleaning and Inspection............................................................. 772 Assembly............................................................................ 772 HOIST UP LIMIT SOLENOID VALVE........................................................... 773 HOIST CYLINDERS......................................................................... 773 Removal............................................................................. 773 Installation........................................................................ 774 Disassembly......................................................................... 777 Cleaning and Inspection............................................................. 778 SS1143 Tightening Tool - Assembly Drawing........................................... 779 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 779 Quill Installation.................................................................. 779 Installation Of Check Balls And Plugs In Quill...................................... 780 Assembly of Cylinder................................................................ 782 COUNTERBALANCE MANIFOLD................................................................. 783 SECTION L9 - HIGH PRESSURE FILTERS - INDEX...................................................... 785 HYDRAULIC SYSTEM FILTERS.................................................................... 787 HOIST CIRCUIT FILTER.................................................................... 787 Filter Element Replacement.......................................................... 787 Removal............................................................................. 788 Installation........................................................................ 788 Indicator Switch.................................................................... 788 STEERING CIRCUIT FILTER................................................................. 789 Filter Element Replacement.......................................................... 789 Removal............................................................................. 790 Installation........................................................................ 790 Indicator Switch.................................................................... 790 INDICATOR SWITCH........................................................................ 790 Test Procedure...................................................................... 790 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX............................................. 793 HYDRAULIC CHECK-OUT PROCEDURE............................................................... 795 INITIAL START UP AND FLUSHING........................................................... 795 COMPONENT CHECKOUT AND ADJUSTMENT....................................................... 797 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE........................... 799 Counterbalance Valve Adjustment..................................................... 801 Manifold Assembly................................................................... 801 OIL CLEANLINESS CHECK................................................................... 801 Oil Sampling Location On Truck...................................................... 801 Oil Sampling Process and Cleanliness Criteria....................................... 802 DISABLED TRUCK DUMPING PROCEDURE........................................................ 802 Hookup.............................................................................. 802 Raising the Body.................................................................... 802 Lowering the Body................................................................... 803 Troubleshooting Chart............................................................... 804 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX....................................................... 811 SECTION M7 - ENGINE OIL HEATER - INDEX.......................................................... 813 ENGINE OIL HEATERS.......................................................................... 815 GENERAL INFORMATION..................................................................... 815 TROUBLESHOOTING......................................................................... 815 HEATER ELEMENT.......................................................................... 815 Removal............................................................................. 815 Installation........................................................................ 816 SECTION M8 -SPECIAL TOOLS....................................................................... 817 SECTION N - OPERATOR'S CAB - INDEX.................................................................. 827 SECTION N2 - TRUCK CAB - INDEX.................................................................. 829 TRUCK CAB................................................................................... 831 TRUCK CAB............................................................................... 831 Description......................................................................... 831 Removal............................................................................. 832 Installation........................................................................ 834 CAB DOOR................................................................................ 834 Removal............................................................................. 834 Installation........................................................................ 835 Door Adjustment..................................................................... 835 Door Jam Bolt Adjustment............................................................ 835 Door Handle Plunger Adjustment...................................................... 837 Replace Door Glass.................................................................. 838 Replace Door Window Regulator....................................................... 842 Replace Door Handle or Latch Assembly............................................... 842 Door and Door Hinge Seal Replacement................................................ 843 Door Opening Seal Removal........................................................... 843 Installation........................................................................ 843 GLASS REPLACEMENT....................................................................... 844 Adhesive-Bonded Windows............................................................. 844 Recommended Tools/Supplies.......................................................... 844 Replacement Procedure............................................................... 844 Windshield and Rear Glass........................................................... 845 Removal............................................................................. 845 Installation........................................................................ 846 SECTION N3 - CAB COMPONENTS - INDEX............................................................. 847 CAB COMPONENTS.............................................................................. 849 WINDSHIELD WIPERS....................................................................... 849 WIPER MOTOR REPLACEMENT............................................................. 849 Removal......................................................................... 849 Installation.................................................................... 849 WIPER ARM REPLACEMENT............................................................... 849 Removal......................................................................... 849 Installation.................................................................... 850 WIPER LINKAGE REPLACEMENT........................................................... 850 Removal......................................................................... 850 Installation.................................................................... 851 WINDSHIELD WASHER................................................................... 851 Operation....................................................................... 851 Service......................................................................... 851 SECTION N4 - OPERATOR COMFORT - INDEX........................................................... 853 HEATER/AIR CONDITIONER...................................................................... 855 CONTROLS................................................................................ 855 Operation........................................................................... 855 Heater/Air Conditioner Vents........................................................ 855 Defroster Vent Control Switch....................................................... 855 Heat Control Switch................................................................. 855 Temperature Control Knob............................................................ 855 Fan Control Knob.................................................................... 855 Heater/Air Conditioner Selector Switch.............................................. 855 COMPONENTS.............................................................................. 856 Circuit Breakers.................................................................... 856 Relays.............................................................................. 856 Heater Core......................................................................... 856 Fan Motor and Speed Control......................................................... 857 Test................................................................................ 857 Actuators........................................................................... 857 Test................................................................................ 857 Cab Air Filter...................................................................... 858 AIR CONDITIONING SYSTEM..................................................................... 860 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................... 861 PRINCIPLES OF REFRIGERATION............................................................. 861 Air Conditioning.................................................................... 861 Refrigeration - The Act of Cooling.................................................. 862 The Refrigeration Cycle............................................................. 862 AIR CONDITIONER SYSTEM COMPONENTS....................................................... 863 Compressor (Refrigerant Pump)....................................................... 863 Service Valves...................................................................... 863 Receiver-Drier...................................................................... 863 Condenser........................................................................... 863 Expansion Block Valve............................................................... 864 Accumulator......................................................................... 864 Evaporator.......................................................................... 865 ELECTRICAL CIRCUIT...................................................................... 865 Thermostat.......................................................................... 865 Compressor Clutch................................................................... 866 Trinary™ Switch..................................................................... 866 SYSTEM SERVICING........................................................................ 868 SERVICE TOOLS AND EQUIPMENT............................................................. 869 Recovery/Recycle Station............................................................ 869 Leak Detector....................................................................... 870 Service Valves...................................................................... 870 Vacuum Pump......................................................................... 870 Manifold Gauge Set.................................................................. 871 Low Side Gauge...................................................................... 871 High Side Gauge..................................................................... 871 Installing Manifold Gauge Set....................................................... 872 Purging Air From Service Hoses...................................................... 872 SYSTEM PERFORMANCE TEST................................................................. 873 SYSTEM OIL.............................................................................. 874 Handling and Reusing RPAG Oil....................................................... 874 Oil Quantity........................................................................ 874 Checking System Oil................................................................. 874 REFRIGERANT............................................................................. 875 Recycled Refrigerant................................................................ 875 Reclaimed Refrigerant............................................................... 875 Refrigerant Quantity................................................................ 876 R-134a Refrigerant Containers....................................................... 876 SYSTEM LEAK TESTING..................................................................... 876 Electronic Leak Detector............................................................ 877 Tracer Dyes......................................................................... 877 Soap and Water...................................................................... 877 RECOVERING AND RECYCLING THE REFRIGERANT................................................ 878 Performing the Recovery Cycle....................................................... 878 Performing the Recycling Procedure.................................................. 878 Evacuating and Charging the A/C System.............................................. 878 SYSTEM REPAIR........................................................................... 879 System Flushing..................................................................... 879 COMPONENT REPLACEMENT................................................................... 880 Hoses and Fittings.................................................................. 880 Lines............................................................................... 880 Expansion Valve..................................................................... 880 Receiver-Drier...................................................................... 880 Thermostat.......................................................................... 880 Compressor.......................................................................... 881 Accumulator......................................................................... 881 Clutch.............................................................................. 881 Servicing the Compressor Clutch..................................................... 882 Pulley Removal...................................................................... 884 Clutch Coil Check................................................................... 885 Pulley Installation................................................................. 885 Clutch Assembly Installation........................................................ 886 EVACUATING THE SYSTEM................................................................... 887 CHARGING THE A/C SYSTEM................................................................. 889 AIR CONDITIONER DRIVE BELT.............................................................. 890 Pulley Alignment.................................................................... 890 Belt Tension........................................................................ 891 TROUBLESHOOTING......................................................................... 892 Preliminary Checks.................................................................. 892 Diagnosis of Gauge Readings and System Performance.................................. 892 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.......................................... 893 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM........................................ 899 SECTION N5 - OPERATOR CONTROLS AND EQUIPMENT - INDEX............................................ 901 OPERATOR CONTROLS AND EQUIPMENT............................................................. 903 STEERING WHEEL AND CONTROLS............................................................. 904 STEERING WHEEL...................................................................... 904 HORN BUTTON......................................................................... 904 TILT/TELESCOPE LEVER................................................................ 904 M ULTI-FUNCTION TURN SIGNAL SWITCH.................................................. 904 Turn Signal Operation........................................................... 905 High Beam Headlight Operation................................................... 905 Windshield Wiper Operation...................................................... 905 STEERING COLUMN..................................................................... 905 Removal......................................................................... 905 Inspection...................................................................... 906 Installation.................................................................... 906 PEDALS.................................................................................. 906 SERVICE BRAKE PEDAL................................................................. 906 DYNAMIC RETARDER PEDAL.............................................................. 907 Optional - Dual Function/Single Pedal........................................... 907 THROTTLE PEDAL...................................................................... 907 OVERHEAD PANEL CONTROLS AND COMPONENTS.............................................. 908 GRADE/SPEED WARNING CHART........................................................... 908 RADIO SPEAKERS...................................................................... 908 WARNING ALARM BUZZER................................................................ 908 CAB RADIO........................................................................... 908 WARNING LIGHTS DIMMER CONTROL....................................................... 908 WARNING/STATUS INDICATOR LIGHT PANEL................................................ 908 CENTER CONSOLE.......................................................................... 909 AIR CLEANER VACUUM GAUGES........................................................... 909 WINDSHIELD WIPERS................................................................... 909 TRUCK CONTROLS...................................................................... 910 F-N-R Selector Switch........................................................... 910 Hoist Control Lever............................................................. 910 CONSOLE SWITCHES AND CONTROLS....................................................... 910 Ashtray......................................................................... 910 Cigarette Lighter............................................................... 910 Left-Hand Window Control Switch................................................. 910 Right-Hand Window Control Switch................................................ 910 Engine Shutdown Switch.......................................................... 911 Override Switch................................................................. 911 Retard Speed Control (RSC) Switch............................................... 911 Retard Speed Control (RSC) Dial................................................. 911 Statex III Download Port........................................................ 912 Engine Diagnostic Port (CENSE).................................................. 912 Modular Mining Port............................................................. 912 Passenger Seat.................................................................. 912 Engine Diagnostic Connectors.................................................... 912 Engine Diagnostics Connector.................................................... 912 Data Storage Button............................................................. 912 PAYLOAD METER....................................................................... 913 Payload Meter Download Connector................................................ 913 CAB CLIMATE CONTROL..................................................................... 914 HEATER/AIR CONDITIONER VENTS........................................................ 914 HEATER/AIR CONDITIONER CONTROLS AND VENTS........................................... 914 Defroster Vent Control Switch................................................... 914 Heat Control Switch............................................................. 914 Temperature Control Knob........................................................ 914 Fan Control Knob................................................................ 914 Heater/Air Conditioner Vents.................................................... 914 OPERATOR SEAT........................................................................... 915 ADJUSTMENT.......................................................................... 915 INSTRUMENT PANEL........................................................................ 916 GENERAL INFORMATION................................................................. 916 CONTROL SYMBOLS..................................................................... 916 CONTROL SWITCHES AND GAUGES......................................................... 917 Key Switch...................................................................... 918 Engine Shutdown Switch With Timer Delay......................................... 918 Fog Light Switch................................................................ 918 Ladder Light Switch............................................................. 918 Backup Light Switch............................................................. 918 Panel Illumination Lights....................................................... 918 Cab Air Conditioner/Heater Vents................................................ 918 Engine Cold Weather Starting Aid Switch......................................... 918 Rotating Beacon Light Switch.................................................... 919 Heated Mirror Switch............................................................ 919 Wheel Brake Lock Switch......................................................... 919 Parking Brake Switch............................................................ 919 Digital Tachometer.............................................................. 919 Right Turn Signal Indicator Light............................................... 920 High Beam Headlight Indicator Light............................................. 920 Left Turn Signal Indicator Light................................................ 920 Digital Speedometer/Payload Meter Display....................................... 920 Voltmeter Gauge................................................................. 920 Engine Oil Pressure Gauge....................................................... 920 Engine Water Temperature Gauge.................................................. 920 Fuel Gauge...................................................................... 920 Engine Hourmeter................................................................ 921 Headlight Switch................................................................ 921 Panel Illumination Lights Dimmer Rheostat....................................... 921 Payload Meter Switch............................................................ 921 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL........................................... 922 DESCRIPTION OF INDICATOR SYMBOLS.................................................... 922 INDICATOR LIGHT FUNCTIONS........................................................... 923 High Hydraulic Oil Temperature.................................................. 923 Low Steering Pressure........................................................... 923 Low Accumulator Precharge Pressure Warning...................................... 923 Electric System Fault Warning................................................... 924 Low Brake Pressure Indicator.................................................... 924 Low Hydraulic Tank Level........................................................ 924 Low Automatic Lubrication System Pressure....................................... 924 Circuit Breaker Tripped......................................................... 924 Hydraulic Oil Filter............................................................ 924 Low Fuel Indicator.............................................................. 925 Parking Brake Indicator......................................................... 925 Service Brake Indicator......................................................... 925 Body Up Indicator............................................................... 925 Dynamic Retarding Indicator..................................................... 925 Stop Engine Warning............................................................. 925 Backup Indicator................................................................ 925 Engine Shutdown Timer Switch- Five Minute Idle.................................. 925 Retard Speed Control............................................................ 925 Service Engine Indicator (AEM).................................................. 926 High Wheel Motor Temperature Indicator.......................................... 926 Blower Fault Warning............................................................ 926 Service Engine Indicator (CENSE)................................................ 926 Komatsu Engines w/Centry™ Fuel Control.......................................... 926 Hazard Warning Light Switch..................................................... 926 Lamp Test Switch/Centry™ Diagnostic Test Switch................................. 926 CENTRY™ FUEL SYSTEM DIAGNOSTICS......................................................... 927 GENERAL OPERATION................................................................... 927 DETERMINING FAULT CODES............................................................. 927 EXITING THE DIAGNOSTICS MODE........................................................ 928 SECTION P - LUBRICATION AND SERVICE - INDEX......................................................... 929 SECTION P2 - LUBRICATION AND SERVICE - INDEX.................................................... 931 LUBRICATION AND SERVICE..................................................................... 933 GENERAL INFORMATION..................................................................... 933 HYDRAULIC TANK SERVICE.................................................................. 933 Adding Oil.......................................................................... 933 COOLING SYSTEM.......................................................................... 934 Coolant Level Check................................................................. 934 Radiator Filling Procedure.......................................................... 934 Antifreeze Temperature Recommendations.............................................. 934 10 HOUR LUBE AND MAINTENANCE CHECKS......................................................... 936 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................. 937 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................. 937 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................. 938 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................. 940 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................ 941 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................ 942 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................ 943 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................. 943 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................ 942 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX............................................... 945 AUTOMATIC LUBRICATION SYSTEM................................................................ 947 GENERAL DESCRIPTION..................................................................... 947 SYSTEM COMPONENTS....................................................................... 948 Filter Assembly..................................................................... 948 Hydraulic Motor and Grease Pump..................................................... 948 Reservoir........................................................................... 949 Fixed Pressure Reducing Valve....................................................... 949 Flow Control Valve.................................................................. 949 Solenoid Valve...................................................................... 949 Vent Valve.......................................................................... 949 24VDC Lubrication Cycle Timer....................................................... 949 Time Delay Module................................................................... 949 Pump Cutoff Pressure Switch......................................................... 949 Unloader Valve...................................................................... 949 Pressure Switch..................................................................... 949 Pressure Gauge...................................................................... 951 Manual Override Button.............................................................. 951 Injectors........................................................................... 951 SYSTEM OPERATION........................................................................ 953 Normal Operation.................................................................... 953 Pressure Failure Detection Circuits................................................. 954 GENERAL INSTRUCTIONS........................................................................ 955 LUBRICANT REQUIRED FOR SYSTEM........................................................... 955 SYSTEM PRIMING.......................................................................... 955 LUBRICANT PUMP.......................................................................... 956 Pump Housing Oil Level.............................................................. 956 Pump Pressure Control............................................................... 956 FILTER AND RESERVOIR.................................................................... 956 Filter Assembly Element............................................................. 957 INJECTORS (SL-1 Series H)............................................................... 957 Injector Specifications............................................................. 957 Injector Adjustment................................................................. 957 INJECTOR OPERATION.......................................................................... 959 SYSTEM CHECKOUT......................................................................... 960 Lubrication Cycle Timer Check....................................................... 960 Lubrication Cycle Timer Adjustment.................................................. 961 PREVENTIVE MAINTENANCE INSPECTION....................................................... 961 10 Hour Lubrication System Inspection............................................... 961 100 Hour Inspection................................................................. 961 250 Hour Inspection................................................................. 961 500 Hour Inspection................................................................. 962 1000 Hour Inspection................................................................ 962 PUMP REBUILD............................................................................ 963 Disassembly......................................................................... 963 Cleaning and Inspection............................................................. 964 Assembly............................................................................ 966 VENT VALVE REB UILD..................................................................... 967 Disassembly and Assembly............................................................ 967 SYSTEM TROUBLESHOOTING CHART............................................................ 968 SECTION P4 - MOTORIZED WHEEL MAINTENANCE SCHEDULE - INDEX....................................... 971 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................ 973 AXLE BOX................................................................................ 973 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................ 974 ARMATURE AREA........................................................................... 974 AT TIRE CHANGE.......................................................................... 974 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................ 975 GENERATOR/ALTERNATOR.................................................................... 975 GRID BLOWER MOTOR....................................................................... 975 CONTROL EQUIPMENT CHECKS................................................................ 975 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................ 976 VEHICLE OPERATIONS TESTS................................................................ 976 SECTION R - SYSTEM SCHEMATICS - INDEX............................................................... 977 HYDRAULIC BRAKE SYSTEM SCHEMATIC................................................................ 979 HYDRAULIC SYSTEM SCHEMATIC ..................................................................... 980 ELECTRICAL SCHEMATIC............................................................................ 981 VHMS SYSTEM SCHEMATIC...........................................................................1014
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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