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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30581 – A30602 & A30604 – A30609) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30581 – A30602 & A30604 – A30609
- PUBLICATION NUMBER:CEBM022401
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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30581 – A30602 & A30604 – A30609) KOMATSU 730E
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30581 – A30602 & A30604 – A30609) KOMATSU 730E – PDF DOWNLOAD:
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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30581 – A30602 & A30604 – A30609) KOMATSU 730E
- 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.
TABLE OF CONTENTS:
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30581 – A30602 & A30604 – A30609) KOMATSU 730E
FOREWORD................................................................................................... 5 TABLE OF CONTENTS.......................................................................................... 7 SECTION A GENERAL INFORMATION INDEX........................................................................ 9 MAJOR COMPONENT DESCRIPTION............................................................................ 11 SPECIFICATIONS..................................................................................... 13 Komatsu SSA16V159.............................................................................. 13 GENERAL SAFETY AND OPERATION INDEX..................................................................... 15 GENERAL SAFETY AND OPERATION....................................................................... 18 PERSONAL SAFETY................................................................................ 18 Safety Rules............................................................................... 18 Truck Safety Features...................................................................... 18 Clothing And Personal Items................................................................ 18 Unauthorized Modification.................................................................. 18 Leaving The Operator’s Seat................................................................ 18 Mounting And Dismounting................................................................... 19 Fire Extinguishers And First Aid Kits...................................................... 19 Precautions For High Temperature Fluids.................................................... 19 Asbestos Dust Hazard Prevention............................................................ 20 Fire Prevention For Fuel And Oil........................................................... 20 ROPS Precautions........................................................................... 20 Preventing Injury From Work Equipment...................................................... 20 Precautions For Optional Attachments....................................................... 20 Precautions When Starting The Machine...................................................... 21 PRECAUTIONS FOR TRUCK OPERATION................................................................ 21 Safety Is Thinking Ahead................................................................... 21 Safety At The Work Site.................................................................... 21 Fire Prevention............................................................................ 21 Preparing For Operation.................................................................... 21 Ventilation For Enclosed Areas............................................................. 21 Mirrors, Windows, And Lights............................................................... 22 In The Operator’s Cab - Before Starting The Engine......................................... 22 Seat Belts................................................................................. 22 OPERATING THE MACHINE.......................................................................... 22 Starting The Engine........................................................................ 22 Truck Operation - General.................................................................. 23 Traveling In The Truck..................................................................... 23 Precautions When Traveling In Reverse...................................................... 23 Traveling On Slopes........................................................................ 24 Ensuring Good Visibility................................................................... 24 Operating On Snow.......................................................................... 24 Avoid Damage To The Dump Body.............................................................. 24 Driving Near High-Voltage Cables........................................................... 24 When Loading The Truck..................................................................... 24 When Dumping............................................................................... 24 Working On Loose Ground.................................................................... 25 Parking The Machine........................................................................ 25 TOWING......................................................................................... 25 WORKING NEAR BATTERIES......................................................................... 25 Battery Hazard Prevention.................................................................. 25 Jump-Starting With Booster Cables.......................................................... 26 Jump Starting With Receptacles............................................................. 26 PRECAUTIONS FOR MAINTENANCE........................................................................ 27 BEFORE PERFORMING MAINTENANCE.................................................................. 27 Stopping The Engine Before Service......................................................... 27 Warning Tag................................................................................ 27 Proper Tools............................................................................... 27 Securing The Dump Body..................................................................... 27 DURING MAINTENANCE............................................................................. 28 Personnel.................................................................................. 28 Attachments................................................................................ 28 Working Under The Machine.................................................................. 28 Keeping The Machine Clean.................................................................. 28 Rules To Follow When Adding Fuel Or Oil.................................................... 28 Radiator Coolant Level..................................................................... 28 Use Of Lighting............................................................................ 28 Precautions With The Battery............................................................... 29 Handling High-Pressure Hoses............................................................... 29 Precautions With High-Pressure Oil......................................................... 29 Maintenance Near High Temperatures And High Pressures...................................... 29 Rotating Fan And Belts..................................................................... 29 Waste Materials............................................................................ 29 TIRES.......................................................................................... 30 Handling Tires............................................................................. 30 Tire Maintenance........................................................................... 31 Storing Tires After Removal................................................................ 31 ADDITIONAL JOB SITE RULES.......................................................................... 32 WHEN REPAIRS ARE NECESSARY......................................................................... 33 OPERATING INSTRUCTIONS............................................................................. 34 PREPARING FOR OPERATION........................................................................ 34 SAFETY IS THINKING AHEAD....................................................................... 34 WALK AROUND INSPECTION......................................................................... 34 ENGINE START-UP................................................................................ 38 AFTER ENGINE HAS STARTED....................................................................... 39 EMERGENCY STEERING SYSTEM...................................................................... 40 Operation.................................................................................. 40 Pre-Operation Testing...................................................................... 40 Additional Guidelines...................................................................... 41 MACHINE OPERATION SAFETY PRECAUTIONS........................................................... 41 LOADING........................................................................................ 42 HAULING........................................................................................ 42 PASSING........................................................................................ 43 DUMPING........................................................................................ 43 To Raise The Dump Body:.................................................................... 43 To Lower The Dump Body: (When dumping over a berm or into a crusher):...................... 44 To Lower The Dump Body (When dumping on flat ground):...................................... 44 TOWING......................................................................................... 45 Towing Procedure........................................................................... 45 SAFE PARKING PROCEDURES........................................................................ 46 ENGINE SHUTDOWN PROCEDURE...................................................................... 46 DELAYED ENGINE SHUTDOWN PROCEDURE.............................................................. 46 SUDDEN LOSS OF POWER........................................................................... 47 WARNINGS AND CAUTIONS.................................................................................. 49 STANDARD TORQUE CHARTS AND CONVERSION TABLES........................................................... 57 STORAGE AND IDLE MACHINE PREPARATION INDEX............................................................. 63 STORAGE AND IDLE MACHINE PREPARATION............................................................... 65 SHORT TERM IDLE PERIODS........................................................................ 65 PREPARATION FOR STORAGE........................................................................ 66 REMOVAL FROM STORAGE........................................................................... 67 RECONDITIONING AN IDLE VEHICLE................................................................. 68 ENGINE OPERATION............................................................................... 71 After The Engine Has Started............................................................... 71 ENGINE STORAGE................................................................................. 72 Temporary Storage (30 Days Or Less)........................................................ 72 Extended Storage (More Than 30 Days)....................................................... 73 RESTORING AN ENGINE AFTER EXTENDED STORAGE..................................................... 74 ELECTRIC DRIVE TRUCKS.......................................................................... 75 Storing A Truck That Is Operational........................................................ 75 Storing A Truck That Is Not Operational.................................................... 76 Storing A Major Component.................................................................. 77 Periodic Inspections....................................................................... 77 Placing Equipment Into Service After Storage............................................... 77 SECTION B STRUCTURES INDEX................................................................................. 79 STRUCTURAL COMPONENTS INDEX............................................................................ 81 STRUCTURAL COMPONENTS.............................................................................. 83 LADDERS........................................................................................ 83 Removal.................................................................................... 83 Installation............................................................................... 83 GRILLE AND HOOD................................................................................ 84 Removal.................................................................................... 84 Installation............................................................................... 84 RIGHT-HAND DECK................................................................................ 84 Removal.................................................................................... 84 Installation............................................................................... 86 CENTER DECK.................................................................................... 86 LEFT-HAND DECK................................................................................. 87 Removal.................................................................................... 87 Installation............................................................................... 87 DUMP BODY INDEX........................................................................................ 89 DUMP BODY.......................................................................................... 91 DUMP BODY...................................................................................... 91 Removal.................................................................................... 91 Installation............................................................................... 92 BODY SLING..................................................................................... 92 BODY PADS...................................................................................... 93 Adjustment................................................................................. 93 BODY GUIDE..................................................................................... 94 BODY POSITION INDICATOR........................................................................ 94 HOIST LIMIT SWITCH............................................................................. 94 ROCK EJECTORS.................................................................................. 94 Inspection................................................................................. 94 FUEL TANK INDEX........................................................................................ 95 FUEL TANK.......................................................................................... 97 Removal........................................................................................ 97 Repair......................................................................................... 97 Cleaning....................................................................................... 97 Installation................................................................................... 98 FUEL GAUGE SENDER.................................................................................. 99 Removal........................................................................................ 99 Installation................................................................................... 99 LOW FUEL SENDER.................................................................................... 100 Removal........................................................................................ 100 Installation................................................................................... 100 TANK BREATHER VALVE................................................................................ 101 Removal........................................................................................ 101 Installation................................................................................... 101 Disassembly.................................................................................... 101 Assembly....................................................................................... 101 FUEL RECEIVER (WIGGINS QUICK FILL)................................................................. 102 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)............................................ 103 SECTION C ENGINE INDEX..................................................................................... 105 POWER MODULE INDEX..................................................................................... 107 POWER MODULE....................................................................................... 109 GENERAL INFORMATION............................................................................ 109 POWER MODULE SERVICE........................................................................... 110 Removal.................................................................................... 110 Installation............................................................................... 114 COOLING SYSTEM INDEX................................................................................... 117 COOLING SYSTEM..................................................................................... 119 RADIATOR....................................................................................... 119 Removal.................................................................................... 119 Service.................................................................................... 120 Installation............................................................................... 120 RADIATOR FILL PROCEDURE.................................................................... 121 RADIATOR REPAIR............................................................................ 121 Internal Inspection.................................................................... 121 External Cleaning...................................................................... 122 Disassembly............................................................................ 122 Cleaning and Inspection................................................................ 123 Assembly............................................................................... 123 Additional Service Information......................................................... 125 PRESSURE TESTING........................................................................... 125 COOLANT SYSTEM TROUBLESHOOTING............................................................. 125 POWER TRAIN INDEX...................................................................................... 127 POWER TRAIN........................................................................................ 129 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.................................................. 129 General Information........................................................................ 129 Removal.................................................................................... 129 ALTERNATOR INSTALLATION........................................................................ 131 Engine/Alternator Mating................................................................... 131 Alternator Measurement..................................................................... 131 Engine End Play Measurement................................................................ 132 Determining Shim Requirements.............................................................. 133 Installing Alternator On Engine............................................................ 134 ENGINE......................................................................................... 135 Removal.................................................................................... 135 Installation............................................................................... 135 AIR CLEANERS INDEX..................................................................................... 137 AIR CLEANERS....................................................................................... 139 OPERATION...................................................................................... 139 SERVICING THE AIR CLEANERS..................................................................... 139 Replacing The Elements..................................................................... 140 AIR CLEANER ASSEMBLY CLEANING.................................................................. 141 Primary Element Cleaning................................................................... 141 Precleaner Section Cleaning................................................................ 143 AIR INTAKE TROUBLESHOOTING..................................................................... 144 FAN DRIVE CLUTCH INDEX................................................................................. 145 FAN DRIVE CLUTCH................................................................................... 147 COMPONENTS..................................................................................... 147 Input...................................................................................... 147 Output..................................................................................... 147 Stationary Components...................................................................... 148 OPERATIONAL MODES.............................................................................. 149 Fully Engaged.............................................................................. 149 Modulated Variable Speed................................................................... 149 Fully Released............................................................................. 150 Lubricating and Cooling Oil................................................................ 151 MAINTENANCE.................................................................................... 152 TROUBLESHOOTING................................................................................ 153 Preliminary Checks......................................................................... 153 FIELD CHECK DIAGNOSIS.......................................................................... 154 Preliminary Checks - Engine Off............................................................ 154 Check Clutch Release....................................................................... 154 Check Clutch Lock-up....................................................................... 155 Overheating................................................................................ 155 Thermal Sensor and Solenoid Valve.......................................................... 156 On Truck Test.............................................................................. 156 Off Truck Test............................................................................. 156 TROUBLESHOOTING CHART.............................................................................. 158 FAN CLUTCH DISASSEMBLY INSTRUCTIONS................................................................ 161 REASSEMBLY OF THE FAN CLUTCH....................................................................... 168 INSPECTION OF PARTS................................................................................ 179 REBUILD TOOLS...................................................................................... 183 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX................................................... 185 24VDC ELECTRIC SUPPLY SYSTEM INDEX..................................................................... 187 24VDC ELECTRIC SUPPLY SYSTEM....................................................................... 189 ELECTRICAL SYSTEM DESCRIPTION.................................................................. 189 BATTERIES...................................................................................... 189 Maintenance and Service.................................................................... 189 Troubleshooting............................................................................ 189 BATTERY CHARGING ALTERNATOR.................................................................... 191 24VDC ELECTRIC START SYSTEM.................................................................... 191 CRANKING MOTORS............................................................................ 191 Removal................................................................................ 191 Installation........................................................................... 192 CRANKING MOTOR TROUBLESHOOTING............................................................. 192 Preliminary Inspection................................................................. 193 No-Load Test........................................................................... 193 Interpreting Results of Tests.......................................................... 193 Disassembly............................................................................ 194 Cleaning and Inspection................................................................ 194 Armature Servicing..................................................................... 195 Field Coil Checks...................................................................... 197 Field Coil Removal..................................................................... 197 Solenoid Checks........................................................................ 197 Test................................................................................... 197 Assembly............................................................................... 199 Pinion Clearance....................................................................... 200 MAGNETIC SWITCH............................................................................ 200 Coil Test.............................................................................. 200 Electric Start System Wiring Diagrams.................................................. 200 ENGINE PRELUB SYSTEM........................................................................... 201 OPERATION.................................................................................. 201 Pressure Switch........................................................................ 201 Suction Line........................................................................... 201 Outlet Line............................................................................ 201 Check Valve............................................................................ 201 Solenoid Timer......................................................................... 201 TROUBLESHOOTING PRELUB STARTER CIRCUIT............................................................. 203 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX............................................................... 207 24VDC ELECTRICAL SYSTEM COMPONENTS................................................................. 209 PASSENGER SEAT BASE COMPARTMENT................................................................ 209 COMPONENTS..................................................................................... 209 Taillight Resistor Diode Assemblies........................................................ 209 Inclinometer............................................................................... 209 Lubrication System Timer................................................................... 209 Three Minute Idle Timer Components......................................................... 209 Three Minute Idle Timer.................................................................... 211 Idle Timer Relay........................................................................... 211 Three Minute Idle Contactor................................................................ 211 Three Minute Idle Circuit Test............................................................. 211 Data Store Button.......................................................................... 211 Komatsu Engine Diagnostic Connector (Centry)............................................... 211 Komatsu Engine Diagnostic Port (CENSE)..................................................... 211 STATEX III Propulsion System Diagnostic Connector.......................................... 211 Modular Mining Port (Optional)............................................................. 211 Alarm Indicating Device (AID) System....................................................... 212 Diode Matrix (Without Sound)............................................................... 212 Diode Matrix (With Sound).................................................................. 213 Hot Switch Inverter........................................................................ 213 Hot Switch Inverter Card (Slot 4) (Not Used)............................................... 213 Temperature................................................................................ 213 Oil Level.................................................................................. 213 Temperature and Latch...................................................................... 213 Coolant Level/Flasher...................................................................... 214 Lamp Test.................................................................................. 214 BATTERY EQUALIZER BOX.......................................................................... 214 Troubleshooting............................................................................ 214 BODY POSITION SWITCHES......................................................................... 216 Proximity Switch Operation................................................................. 216 Body-Up Switch Adjustment.................................................................. 217 Hoist Limit Switch Adjustment.............................................................. 217 24-VOLT RELAY AND DIODE BOARDS................................................................. 219 RELAY BOARDS................................................................................... 220 Description................................................................................ 220 SERVICE........................................................................................ 220 To Replace A Relay:........................................................................ 220 To Replace A Circuit Breaker:.............................................................. 220 To Replace A Circuit Panel Card............................................................ 221 Relay Board Components..................................................................... 221 Installing Additional Circuits............................................................. 222 DIODE BOARD 1.............................................................................. 223 Diode Testing.............................................................................. 223 CIRCUIT BREAKERS............................................................................... 225 CHARGING SYSTEM INDEX.................................................................................. 227 CHARGING SYSTEM.................................................................................... 229 CHARGING SYSTEM DESCRIPTION.................................................................... 229 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION.............................................. 229 Excessive heat......................................................................... 229 Dirt and dust.......................................................................... 229 Vibration.............................................................................. 229 PREVENTIVE MAINTENANCE PROCEDURES.......................................................... 230 Alternator Cleanliness................................................................. 230 Alternator Mounting.................................................................... 230 Belt Tension And Condition............................................................. 230 TROUBLESHOOTING PROCEDURES..................................................................... 230 ALTERNATOR PERFORMANCE TEST................................................................ 230 ALTERNATOR CABLE TEST...................................................................... 231 VOLTAGE REGULATOR ADJUSTMENT................................................................... 232 ALTERNATOR................................................................................. 233 Removal................................................................................ 233 Installation........................................................................... 234 VHMS COMPONENTS INDEX................................................................................. 237 VEHICLE HEALTH MONITORING SYSTEM (VHMS)............................................................ 239 VHMS BASIC FEATURES............................................................................ 239 Gather Data................................................................................ 239 Convert and Record Data.................................................................... 240 Communicate Data to Off-Board Systems...................................................... 240 USING THE VHMS SYSTEM.......................................................................... 241 Basic Precautions.......................................................................... 241 Turning the VHMS System On................................................................. 241 Normal VHMS Operation...................................................................... 242 Turning the VHMS System Off................................................................ 242 Downloading From the VHMS Controller....................................................... 242 VHMS DATA ITEMS................................................................................ 243 Fault Codes................................................................................ 243 Machine History............................................................................ 243 VHMS History............................................................................... 244 Snapshots.................................................................................. 244 Manual Snapshots........................................................................... 244 Trends..................................................................................... 244 Histogram (Load Map) Data.................................................................. 246 Haul Cycle Data............................................................................ 247 Alarm and Snapshot Triggers................................................................ 248 Satellite Features......................................................................... 250 VHMS DIAGNOSTIC FEATURES....................................................................... 250 Fault History.............................................................................. 250 VHMS LED Digits............................................................................ 250 Light (10) PLM III communication........................................................... 250 Light (11) OrbComm......................................................................... 250 VHMS COMPONENTS.................................................................................... 251 VHMS CONTROLLER................................................................................ 251 Removal.................................................................................... 252 Installation............................................................................... 252 OrbComm Controller......................................................................... 253 Removal.................................................................................... 253 Installation............................................................................... 254 INTERFACE MODULE............................................................................... 254 Inputs..................................................................................... 255 Outputs.................................................................................... 255 Removal.................................................................................... 255 Installation............................................................................... 255 COMPONENT LOCATION............................................................................. 256 Circuit Breakers........................................................................... 256 Temperature Sensors........................................................................ 257 Pressure Sensors........................................................................... 258 VHMS SOFTWARE INDEX................................................................................... 259 VHMS SOFTWARE...................................................................................... 261 Necessary Software............................................................................. 261 Necessary Tools................................................................................ 262 VHMS TOOL BOX INSTALLATION..................................................................... 262 VHMS SETTING TOOL INSTALLATION................................................................. 263 VHMS INITIALIZATION PROCEDURE.................................................................. 263 Preliminary Checks......................................................................... 263 Initialization Steps....................................................................... 263 Select Operation........................................................................... 264 VHMS Setting Function...................................................................... 264 Machine Information Setting(1)............................................................. 264 Machine Information Setting(2)............................................................. 264 Date and Time Setting...................................................................... 265 GCC Setting................................................................................ 265 Setting Summary............................................................................ 265 VHMS SNAPSHOT PROCEDURE........................................................................ 266 VHMS DOWNLOAD.................................................................................. 266 VHMS FTP UPLOAD................................................................................ 267 LOCATION OF DOWNLOAD FILES..................................................................... 268 INSTALLING FLASHBURN PROGRAM................................................................... 269 INSTALLING APPLICATION CODE INTO INTERFACE MODULE.............................................. 269 INSTALLING REALTIME MONITOR SOFTWARE PROGRAM................................................... 270 WHEN REPLACING A VHMS CONTROLLER............................................................... 270 To Set: Date and time, satellite, payload meter............................................ 272 Review Setting Information................................................................. 274 VHMS CHECKOUT AND TROUBLESHOOTING INDEX................................................................ 275 VHMS CHECKOUT AND TROUBLESHOOTING.................................................................. 277 VHMS CHECKOUT PROCEDURE........................................................................ 277 General.................................................................................... 277 Structure and Purpose...................................................................... 278 Necessary Equipment:....................................................................... 278 VHMS SYSTEM CHECKOUT........................................................................... 278 Preliminary................................................................................ 278 Checking Inputs To The Interface Module.................................................... 279 For 930E & 960E trucks only:............................................................... 281 For 830E trucks only:...................................................................... 281 Checking Outputs From The Interface Module................................................. 282 For 830E only:............................................................................. 282 For 930E & 960E only:...................................................................... 282 VHMS CONTROLLER CHECKOUT....................................................................... 282 TROUBLESHOOTING................................................................................ 283 Communications Networks.................................................................... 283 Coaxial Cable.............................................................................. 283 VHMS COMPONENTS................................................................................ 284 VHMS Controller............................................................................ 284 OrbComm Controller......................................................................... 285 Interface Module........................................................................... 285 FAULT CODES.................................................................................... 286 Fault History.............................................................................. 286 VHMS LED Display Fault Codes............................................................... 287 Chassis Fault Codes........................................................................ 288 Engine Fault Codes......................................................................... 292 FAULT TREE ANALYSIS............................................................................ 298 Unable to connect to VHMS from laptop PC................................................... 298 Flashing Error Code N4-23 (PLM III Communications Fault)................................... 299 Flashing Error Code N4-22 (Engine Communications Fault).................................... 300 No Data Received By WebCARE................................................................ 301 Coaxial Cable Troubleshooting.............................................................. 302 VHMS FORMS INDEX....................................................................................... 303 VHMS FORMS......................................................................................... 305 VHMS INITIALIZATION CHECK LIST................................................................. 305 VHMS DATA DOWNLOAD............................................................................. 306 VHMS INITIALIZATION FORM....................................................................... 306 VHMS INITIALIZATION CHECK LIST................................................................. 308 VHMS INITIALIZATION FORM....................................................................... 310 PAYLOAD METER III INDEX................................................................................ 311 OPERATION SECTION.................................................................................. 315 Introduction................................................................................... 315 Data Summary............................................................................... 315 Data Gathering............................................................................. 315 COMPONENT DESCRIPTION.......................................................................... 316 System Diagram............................................................................. 316 Suspension Pressure Sensors................................................................ 316 Inclinometer............................................................................... 316 Operator Display........................................................................... 316 Operator Switch............................................................................ 317 Speed Input................................................................................ 317 Body-Up Switch............................................................................. 317 Brake Lock Switch.......................................................................... 317 Payload Meter.............................................................................. 317 Communications Ports....................................................................... 317 Key Switch Input........................................................................... 318 Payload Meter Power........................................................................ 318 Load Lights................................................................................ 318 Wiring and Termination..................................................................... 319 TCI Outputs................................................................................ 319 OPERATOR’S DISPLAY AND SWITCH.................................................................. 320 Reading the Speedometer.................................................................... 320 Reading the Load Display................................................................... 320 Using the Operator ID...................................................................... 320 Using the Load and Ton Counter............................................................. 320 Total Ton Counter.......................................................................... 320 Total Load Counter......................................................................... 321 Clearing the Counters...................................................................... 321 Viewing Live Sensor Data................................................................... 321 Other Display Messages..................................................................... 321 PAYLOAD OPERATION & CALCULATION................................................................ 322 Description of Haul Cycle States........................................................... 322 Haul Cycle Description..................................................................... 322 Load Calculation........................................................................... 323 Carry Back................................................................................. 323 Measurement Accuracy....................................................................... 323 SOURCES FOR PAYLOAD ERROR...................................................................... 323 Payload Error.............................................................................. 323 Loading Conditions......................................................................... 324 Pressure Sensors........................................................................... 324 Swingloads................................................................................. 324 Speed and Distance......................................................................... 324 HAUL CYCLE DATA................................................................................ 324 Haul Cycle Warning Flags................................................................... 326 Frame Torque Data.......................................................................... 327 Sprung Weight Data......................................................................... 327 Maximum Speed Data......................................................................... 327 Alarm Records.............................................................................. 327 Fault Code Data............................................................................ 328 PC SOFTWARE OVERVIEW........................................................................... 329 System Configuration....................................................................... 329 Installing the PLMIII Software............................................................. 329 DOWNLOADING DATA............................................................................... 330 PLM III SYSTEM CONFIGURATION................................................................... 331 Starting Communications.................................................................... 331 Displayed Payload Units.................................................................... 331 Time Units................................................................................. 331 Connection Menu............................................................................ 331 Connecting to the Payload Meter............................................................ 332 Configure the Payload Meter................................................................ 332 Setting the Date and Time.................................................................. 332 Setting the Truck Type..................................................................... 333 Setting the Gauge Display Units............................................................ 333 Setting the Frame Serial Number............................................................ 333 Setting the Truck Number................................................................... 333 Setting the Komatsu Distributor............................................................ 333 Setting the Komatsu Customer............................................................... 333 Clean Truck Tare........................................................................... 334 Inclinometer Calibration................................................................... 334 DATA ANALYSIS.................................................................................. 335 Creating a Query........................................................................... 335 Sorting on Truck Unit Number............................................................... 335 Sorting on Truck Type...................................................................... 335 Sorting on Date Range...................................................................... 336 Sorting on Time Range...................................................................... 336 Payload Detail Screen...................................................................... 337 Creating Reports........................................................................... 337 Summary - one page report.................................................................. 338 Detailed - multi-page report............................................................... 338 Creating Graphs............................................................................ 339 Exporting Data............................................................................. 339 CSV Export................................................................................. 339 Compressed................................................................................. 340 Importing Data............................................................................. 341 Deleting Haul Cycle Records................................................................ 341 Viewing Alarms............................................................................. 342 Deleting Alarm Records..................................................................... 342 TROUBLESHOOTING SECTION............................................................................ 343 TROUBLESHOOTING................................................................................ 343 Viewing Active Alarms...................................................................... 343 Real-Time Data Display..................................................................... 343 Testing the Payload Lights................................................................. 343 Creating Log Files of Inputs............................................................... 344 Daily Inspections.......................................................................... 344 Periodic Maintenance....................................................................... 344 Abnormal Displays at Power-Up.............................................................. 345 No Payload Display When Key Switch is Turned ON............................................ 346 No Display on Speedometer.................................................................. 347 No Display on Operator Display............................................................. 347 No Communications With PC.................................................................. 348 Load Lights Don’t Light During Loading..................................................... 349 Load Lights Remain ON...................................................................... 350 Load Lights Remain ON During Dumping....................................................... 350 Display Doesn't Clear When The Load Is Dumped.............................................. 350 Calibration Problems....................................................................... 351 Alarm 1 - Left Front Pressure High......................................................... 352 Alarm 2 - Left Front Pressure Low.......................................................... 352 Troubleshoot Wiring to Left Front Suspension............................................... 352 Alarm 3 - Right Front Pressure High........................................................ 353 Alarm 4 - Right Front Pressure Low......................................................... 353 Troubleshoot Wiring to Right Front Suspension.............................................. 353 Alarm 5 -Left Rear Pressure High........................................................... 354 Alarm 6 - Left Rear Pressure Low........................................................... 354 Troubleshoot Wiring to Left Rear Suspension................................................ 354 Alarm 7 - Right Rear Pressure High......................................................... 355 Alarm 8 - Right Rear Pressure Low.......................................................... 355 Troubleshoot Wiring to Right Rear Suspension............................................... 355 Alarm 9 - Inclinometer High................................................................ 356 Alarm 10 - Inclinometer Low................................................................ 356 Troubleshoot Inclinometer Wiring........................................................... 356 Alarm 13 - Body Up Input Failure........................................................... 357 Alarm 16 - Memory Write Failure............................................................ 358 Alarm 17 - Memory Read Failure............................................................. 358 Alarm 18................................................................................... 359 Alarm 19................................................................................... 359 Alarm 22................................................................................... 359 Operator Switch Doesn't Work............................................................... 360 Alarm 26 - User Switch Fault - SELECT...................................................... 360 Alarm 27 - User Switch Fault - SET......................................................... 360 Connector Map.............................................................................. 361 Connectors................................................................................. 362 PLMIII CHECK OUT PROCEDURE......................................................................... 363 General Description............................................................................ 363 Tools Required................................................................................. 363 Checkout Procedure............................................................................. 363 PLMIII CHECKOUT PROCEDURE CONFIRMATION......................................................... 367 Flashburn Programming...................................................................... 367 Confirmation Checklist..................................................................... 369 SECTION E ELECTRICAL PROPULSION INDEX...................................................................... 371 ELECTRICAL PROPULSION COMPONENTS INDEX................................................................. 373 ELECTRICAL PROPULSION COMPONENTS................................................................... 377 GENERAL SYSTEM DESCRIPTION..................................................................... 377 CONTROL SYSTEM................................................................................. 377 System Operation........................................................................... 378 FL275 Panel................................................................................ 379 CARD REPLACEMENT............................................................................... 380 Removal.................................................................................... 380 Installation............................................................................... 380 Card Repair................................................................................ 380 Panel Wiring............................................................................... 380 COMPUTER DESCRIPTION........................................................................... 381 Microprocessor............................................................................. 381 Download Capability........................................................................ 381 SOFTWARE....................................................................................... 381 Base Monitor Program....................................................................... 381 Runtime Monitor Program - OBJ Running Code................................................. 381 Configuration Software - CFG............................................................... 382 PTU - Portable Test Unit Code.............................................................. 382 System Regulation.......................................................................... 382 Propulsion................................................................................. 383 Retarding.................................................................................. 383 TWO-DIGIT DISPLAY PANEL........................................................................ 384 The Coded Number........................................................................... 384 Events..................................................................................... 384 Frames..................................................................................... 385 Windows.................................................................................... 385 System Categories.......................................................................... 385 Limits On Resetting Faults................................................................. 385 NA Faults.................................................................................. 386 Event Sequence............................................................................. 386 Resetting Events........................................................................... 386 Event Descriptions......................................................................... 386 Subcode Descriptions....................................................................... 386 2-DIGIT DISPLAY PANEL SUBCODES................................................................. 394 PORTABLE TEST UNIT (PTU)........................................................................... 397 DESCRIPTION.................................................................................... 397 Operational Hints.......................................................................... 397 SOFTWARE INSTALLATION PREPARATION.............................................................. 398 HARD DISK SPACE REQUIREMENTS................................................................... 398 SOFTWARE INSTALLATION ON PTU................................................................... 398 PTU/Truck Communication Problems........................................................... 399 THE MAIN MENU.................................................................................. 400 Quit Menu.................................................................................. 400 PTU Talk To Truck.......................................................................... 400 View PTU Saved Files....................................................................... 400 List Stat Data Files....................................................................... 400 Truck Setup (CFG).......................................................................... 400 Select Truck Setup......................................................................... 400 Update CFG Version......................................................................... 400 Change PTU Password........................................................................ 400 CONFIGURATION (CFG) FILE CONVERSION............................................................ 402 Conversion Procedure....................................................................... 402 Convert Old CFG files for New software..................................................... 403 STATEX CONFIGURATION FILES..................................................................... 406 0) Source Directory: . . .................................................................. 406 1) Select A Truck Configuration . . ....................................................... 407 2) View Truck Configuration: Data Curves . . .............................................. 408 3) Change/View Serial and Model Numbers . . ............................................... 409 4) View Options . . ....................................................................... 409 5) Change/View Truck Specifics . . ........................................................ 411 6) Change/View Overspeeds . . ............................................................. 413 7) Save a Truck Configuration, filename: . . .............................................. 414 8) Save Directory: . . .................................................................... 415 CHANGE PTU PASSWORD............................................................................ 416 PROGRAMMING THE TRUCK.......................................................................... 417 Connect PTU to the Truck................................................................... 417 Select Configuration File.................................................................. 417 Activate The PTU Mode...................................................................... 417 Check Object Code Version.................................................................. 418 Download Configuration Files............................................................... 419 Date And Time.............................................................................. 420 Event Data................................................................................. 421 Statistical Data........................................................................... 423 View Counters.............................................................................. 423 View Profiles.............................................................................. 423 Upload Statistical Data To A File.......................................................... 423 Statistical Data Codes - Counters.......................................................... 424 STATISTICAL DATA CODES - COUNTERS.............................................................. 425 STATISTICAL DATA CODES - PROFILES.............................................................. 430 TRUCK SPECIFIC INFORMATION..................................................................... 434 Temporary Truck Settings................................................................... 435 MISCELLANEOUS FEATURES......................................................................... 436 Saving Data................................................................................ 436 PTU Abbreviations.......................................................................... 437 Other Menu Selections...................................................................... 437 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..................................................... 438 ALTERNATOR..................................................................................... 438 ELECTRIC WHEEL MOTORS.......................................................................... 438 RETARDING GRIDS................................................................................ 438 ELECTRONIC ACCELERATOR AND RETARD PEDALS....................................................... 438 Removal.................................................................................... 438 Installation............................................................................... 438 Disassembly................................................................................ 439 Reassembly................................................................................. 439 COOLING BLOWER WARNING SYSTEM.................................................................. 439 Operation.................................................................................. 439 Test....................................................................................... 439 Removal.................................................................................... 440 Installation............................................................................... 440 ELECTRICAL CONTROL CABINET......................................................................... 441 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS............................................. 446 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III................................................. 447 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX.................................................. 449 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.................................................... 453 GENERAL INFORMATION............................................................................ 453 COMMUNICATIONS PORT CHECK...................................................................... 454 PTU Hookup................................................................................. 454 4.0 SEQUENCE TESTS - (ENGINE NOT ON)........................................................... 455 Preparation and Setup...................................................................... 455 CONTROL SYSTEM SELF-TEST................................................................... 456 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT................................................... 456 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT..................................................... 457 PTU Setup.............................................................................. 457 4.3 REVERSER AND PROPULSION CONTACTORS CHECK............................................... 458 4.4 NOT USED............................................................................... 459 4.5 RETARD CONTACTORS OPERATION CHECK...................................................... 459 4.6 GROUND FAULT SENSING CHECK............................................................. 459 4.7 GROUND FAULT IN RETARD OPERATION CHECK................................................. 460 4.8 OVERRIDE OPERATION CHECK............................................................... 460 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK...................................................... 461 4.10 OVERSPEED RETARD OPERATION CHECK...................................................... 461 4.11 HOIST INTERLOCK OPERATION CHECK....................................................... 462 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.............................................. 462 Return to Main Menu.................................................................... 462 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL....................................... 463 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.......................................... 463 5.2 DIGITAL INPUT CHECKS................................................................... 464 5.3 DIGITAL OUTPUT CHECKS.................................................................. 465 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL............................................... 469 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU............................................... 469 6.2 ANALOG INPUT CHECKS.................................................................... 470 6.3 FREQUENCY INPUT CHECKS................................................................. 474 Return to Main Menu.................................................................... 475 7.0 SPEED EVENT CHECKS......................................................................... 475 Preparation and Setup...................................................................... 475 Setup PTU.................................................................................. 475 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK................................ 476 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK..................... 476 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK.................... 476 7.4 OTHER SPEED EVENTS CHECKS.............................................................. 476 Return to Main Menu.................................................................... 476 8.0 RETARD SPEED CONTROL SYSTEM CHECK.......................................................... 477 Preparation and Setup...................................................................... 477 Setup PTU.................................................................................. 477 8.1 OVERSPEED PICKUP AND DROPOUT CHECK..................................................... 477 8.2 RETARD POT MAXIMUM SETTING CHECK....................................................... 477 8.3 RETARD POT MINIMUM SETTING CHECK....................................................... 477 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL..................................... 478 Return to Main Menu.................................................................... 478 9.0 LOAD TEST USING TRUCK RETARD GRIDS......................................................... 478 Setup and Preparation...................................................................... 478 PTU Setup.................................................................................. 478 9.1 LOAD TEST.............................................................................. 479 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING.................................................... 479 Setup PTU.................................................................................. 479 10.1 RETARD CHECK.......................................................................... 480 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT............................................... 481 11.1 BRAKE SYSTEM INTERLOCKS CHECK......................................................... 481 Preparation............................................................................ 481 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT................................................ 481 11.3 SYNC TRANSFORMER CHECKOUT............................................................. 482 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT............................................ 482 11.5 BATTERY BOOST ADJUSTMENT.............................................................. 482 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST........................................... 482 11.7 MOTOR ROTATION TEST................................................................... 483 11.8 GROUND FAULT CHECKS................................................................... 483 12.0 MISCELLANEOUS CHARTS...................................................................... 484 12.1 WHEEL MOTOR GEAR RATIOS............................................................... 484 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS........................................................ 485 12.3 ENGINE................................................................................ 486 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX............................................................ 487 TIRES AND RIMS INDEX................................................................................... 489 TIRES AND RIMS..................................................................................... 491 GENERAL INFORMATION............................................................................ 491 TIRES.......................................................................................... 491 Handling Tires............................................................................. 491 Tire Maintenance........................................................................... 492 Storing Tires After Removal................................................................ 492 FRONT TIRES AND RIMS........................................................................... 493 Removal.................................................................................... 493 Installation............................................................................... 494 REAR TIRES AND RIMS............................................................................ 495 Removal.................................................................................... 495 Installation............................................................................... 496 RIM........................................................................................ 497 Tire Removal............................................................................... 497 RIM AND TIRE PREPARATION....................................................................... 498 LUBRICANTS..................................................................................... 498 TIRE INSTALLATION.............................................................................. 499 FRONT WHEEL HUB AND SPINDLE INDEX...................................................................... 501 FRONT WHEEL HUB AND SPINDLE........................................................................ 503 WHEEL HUB AND SPINDLE ASSEMBLY................................................................. 503 Removal.................................................................................... 503 Installation............................................................................... 505 Disassembly................................................................................ 506 Cleaning and Inspection.................................................................... 507 Assembly................................................................................... 507 Wheel Bearing Adjustment (Spindle Vertical)................................................ 510 Wheel Bearing Adjustment (Tire Mounted).................................................... 511 STEERING CYLINDERS AND TIE ROD................................................................. 515 Spherical Bearing Wear Limits.............................................................. 515 Removal.................................................................................... 516 Installation............................................................................... 518 Bearing Replacement........................................................................ 518 TOE-IN ADJUSTMENT.............................................................................. 519 REAR AXLE HOUSING ATTACHMENTS INDEX.................................................................... 521 REAR AXLE HOUSING.................................................................................. 523 PIVOT PIN...................................................................................... 523 Removal.................................................................................... 523 Installation............................................................................... 524 PIVOT EYE BEARING.............................................................................. 524 Disassembly................................................................................ 524 Assembly................................................................................... 525 PIVOT EYE REPAIR............................................................................... 525 Removal.................................................................................... 525 Disassembly................................................................................ 525 Bushing (New).............................................................................. 525 Pivot Eye Bore (New)....................................................................... 525 Assembly................................................................................... 525 Installation............................................................................... 526 ANTI-SWAY BAR.................................................................................. 526 Removal.................................................................................... 526 Installation............................................................................... 526 Disassembly................................................................................ 527 Cleaning and Inspection.................................................................... 527 Assembly................................................................................... 527 REAR AXLE HOUSING INDEX................................................................................ 529 REAR AXLE HOUSING.................................................................................. 531 REAR AXLE HOUSING.............................................................................. 531 Removal.................................................................................... 531 Installation............................................................................... 531 WHEEL MOTOR.................................................................................... 531 Removal.................................................................................... 531 Cleaning and Inspection.................................................................... 532 Installation............................................................................... 532 Maximum Cap Screw Usage.................................................................... 532 SECTION H SUSPENSIONS INDEX................................................................................ 533 FRONT SUSPENSION INDEX................................................................................. 535 FRONT SUSPENSION................................................................................... 537 Removal........................................................................................ 537 Installation................................................................................... 539 Turn-of-the-Nut Tightening Procedure........................................................... 540 Disassembly.................................................................................... 541 Cleaning and Inspection........................................................................ 542 Assembly (Bearing Only)........................................................................ 542 Suspension Assembly (Complete)................................................................. 542 SUSPENSION PRESSURE TEST....................................................................... 544 REAR SUSPENSIONS INDEX................................................................................. 547 REAR SUSPENSIONS................................................................................... 549 Removal........................................................................................ 550 Installation................................................................................... 552 Disassembly.................................................................................... 552 Cleaning and Inspection........................................................................ 553 Assembly....................................................................................... 553 SUSPENSION PRESSURE TEST....................................................................... 555 OILING AND CHARGING PROCEDURES INDEX................................................................... 557 OILING AND CHARGING PROCEDURE...................................................................... 559 GENERAL........................................................................................ 559 EQUIPMENT LIST................................................................................. 559 Hydrair® Charging Kit...................................................................... 559 Installation of Charging Kit............................................................... 559 Removal of Charging Kit.................................................................... 560 Support Blocks For Oiling and Charging Dimensions.......................................... 560 FRONT SUSPENSION............................................................................... 561 Front Suspension Oiling.................................................................... 561 Front Suspension Nitrogen Charging......................................................... 562 REAR SUSPENSION................................................................................ 564 Rear Suspension Oiling..................................................................... 564 Rear Suspension Nitrogen Charging.......................................................... 566 OIL AND NITROGEN SPECIFICATIONS CHART.............................................................. 567 SECTION J BRAKE CIRCUIT INDEX.............................................................................. 569 BRAKE CIRCUIT INDEX.................................................................................... 571 BRAKE CIRCUIT...................................................................................... 573 GENERAL DESCRIPTION............................................................................ 573 SERVICE BRAKE CIRCUIT.......................................................................... 573 SECONDARY BRAKING AND AUTOMATIC APPLY.......................................................... 575 PARKING BRAKE CIRCUIT.......................................................................... 575 Normal Operation (key switch on, engine on)................................................ 575 BRAKE LOCK CIRCUIT............................................................................. 576 WARNING CIRCUIT................................................................................ 576 BRAKE CIRCUIT COMPONENT SERVICE INDEX.................................................................. 579 BRAKE CIRCUIT COMPONENT SERVICE.................................................................... 581 BRAKE VALVE.................................................................................... 581 Rebuild Criteria........................................................................... 581 Removal.................................................................................... 581 Installation............................................................................... 583 Disassembly................................................................................ 585 Cleaning and Inspection.................................................................... 587 ASSEMBLY....................................................................................... 587 Actuator Base Threaded Inserts............................................................. 587 Boot and Cap............................................................................... 587 Valve Body Seal Installation............................................................... 588 Regulator Sleeve O-Ring Installation....................................................... 589 Actuator Plunger O-Ring Installation....................................................... 589 Assembly of Valve.......................................................................... 589 DIFFERENTIAL PRESSURE SWITCH................................................................... 590 Disassembly................................................................................ 591 Cleaning and Inspection.................................................................... 591 Assembly................................................................................... 591 VALVE BENCH TEST AND ADJUSTMENT................................................................ 591 Test Set Up Procedure...................................................................... 593 Brake Valve Output Pressure Adjustment..................................................... 593 Differential Pressure Switch Test.......................................................... 594 Final Test and Adjustment.................................................................. 594 Installation Of Brake Pedal Actuator Assembly to Brake Valve............................... 595 HYDRAULIC BRAKE ACCUMULATORS................................................................... 597 Brake Accumulator Bleed-Down Procedure..................................................... 597 Removal.................................................................................... 597 Installation............................................................................... 599 Disassembly................................................................................ 599 Cleaning and Inspection.................................................................... 601 Assembly................................................................................... 601 Leak Testing............................................................................... 604 BRAKE ACCUMULATOR CHARGING..................................................................... 605 Temperature During Precharge............................................................... 607 ACCUMULATOR STORAGE............................................................................ 607 Installation............................................................................... 608 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX................................................................ 609 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................................. 611 EQUIPMENT REQUIRED............................................................................. 614 INITIAL SYSTEM SET-UP.......................................................................... 615 Parking Brake.............................................................................. 615 Service Brakes............................................................................. 616 Brake Lock/Secondary....................................................................... 616 Low Brake Pressure and Auto Apply.......................................................... 617 Reapplications............................................................................. 617 Differential Pressure Switch............................................................... 617 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...................................................... 619 The Brakes are Locked, Service, and/or Parking................................................. 619 Both Brake Circuits are Dragging............................................................... 619 One Brake Circuit is Dragging.................................................................. 619 Brakes are Not Going to Full Pressure.......................................................... 619 A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off......................... 619 Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released.... 620 Differential Pressure Warning Circuit is Not Operating......................................... 620 A Low Brake Pressure Warning Occurs When Brakes are Applied.................................... 620 Low Pressure Warning Circuit Not Operating Properly............................................ 620 Low Pressure Warning is On Even Though System Pressure is Correct.............................. 621 Low Pressure Warning Comes On and Pressure is Low.............................................. 621 A Squeal is Heard When Controller is Operated.................................................. 621 Output Pressure At Controller is Correct but Brakes are Not Applying........................... 621 Brake Pressures Drift Excessively While Pedal is Held Steady................................... 621 Oil is Leaking Around the Pedal Base........................................................... 621 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM....................... 621 CHECK-OUT PROCEDURE................................................................................ 622 HYDRAULIC BRAKE SYSTEM DATA SHEET.................................................................. 622 FRONT DISC BRAKES INDEX................................................................................ 625 FRONT DISC BRAKES.................................................................................. 627 BRAKE CALIPER.................................................................................. 627 Removal.................................................................................... 627 Installation............................................................................... 628 Disassembly................................................................................ 629 Cleaning and Inspection.................................................................... 629 Assembly................................................................................... 631 BRAKE LINING................................................................................... 631 Replacement................................................................................ 631 FRONT SERVICE BRAKE BURNISHING................................................................. 633 BRAKE BLEEDING PROCEDURE................................................................... 634 REAR BRAKES INDEX...................................................................................... 635 REAR DISC BRAKES................................................................................... 637 REAR BRAKES.................................................................................... 637 CALIPER, DISC, AND PARKING BRAKE............................................................... 637 Removal.................................................................................... 637 Installation............................................................................... 638 CALIPER PISTON................................................................................. 640 Piston Assembly Removal.................................................................... 640 Inspection................................................................................. 640 Piston Assembly Installation............................................................... 641 FUNCTIONAL TEST OF PISTON ASSEMBLY............................................................. 642 Return Spring Force........................................................................ 642 Built-In Clearance......................................................................... 642 Grip Force................................................................................. 644 Grip Force Measurement..................................................................... 645 Spring Force Measurement................................................................... 647 Disassembly of Piston Assembly............................................................. 648 Assembly of Piston Assembly................................................................ 649 BENCH TEST..................................................................................... 649 BRAKE LINING................................................................................... 650 Replacement................................................................................ 650 SERVICE BRAKE BURNISHING....................................................................... 653 SAFETY PRECAUTIONS......................................................................... 653 Rear Brake Burnishing.................................................................. 654 BRAKE BLEEDING PROCEDURE................................................................... 655 Spring Force Measurement............................................................... 656 PARKING BRAKE INDEX.................................................................................... 657 PARKING BRAKE...................................................................................... 659 GENERAL INFORMATION............................................................................ 659 PARKING BRAKE CALIPER.......................................................................... 659 Lining Thickness Inspection................................................................ 659 Removal.................................................................................... 660 Installation............................................................................... 660 Parking Brake Adjustment................................................................... 661 Parking Brake Caliper Disassembly.......................................................... 662 Cleaning and Inspection.................................................................... 663 Parking Brake Caliper Assembly............................................................. 664 PARKING BRAKE LINING REPLACEMENT............................................................... 664 PARKING BRAKE BURNISH PROCEDURE................................................................ 664 Lining Conditioning........................................................................ 664 BRAKE BLEEDING PROCEDURE....................................................................... 665 SECTION L HYDRAULIC SYSTEM INDEX........................................................................... 667 HYDRAULIC SYSTEM INDEX................................................................................. 669 HYDRAULIC SYSTEM................................................................................... 671 GENERAL INFORMATION............................................................................ 671 HYDRAULIC SYSTEMS OPERATION.................................................................... 671 Hoist Circuit Operation.................................................................... 671 Steering Circuit Operation................................................................. 673 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX................................................................ 677 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................................. 679 HOIST PUMP..................................................................................... 679 Removal.................................................................................... 679 Installation............................................................................... 680 Disassembly................................................................................ 681 Inspection of Parts........................................................................ 684 Assembly................................................................................... 684 Troubleshooting Guide...................................................................... 688 HYDRAULIC TANK................................................................................. 689 Filling Instructions....................................................................... 689 Removal.................................................................................... 690 Installation............................................................................... 690 HYDRAULIC TANK STRAINER AND DIFFUSER........................................................... 691 Removal.................................................................................... 691 Inspect and Clean.......................................................................... 692 Installation............................................................................... 692 STEERING CIRCUIT INDEX................................................................................. 693 STEERING CIRCUIT................................................................................... 695 STEERING CIRCUIT OPERATION..................................................................... 695 COMPONENT DESCRIPTION.......................................................................... 696 Steering Control Valve..................................................................... 696 Unloader Valve............................................................................. 697 Bleed-Down Manifold Valve.................................................................. 697 Flow Amplifier............................................................................. 703 FLOW AMPLIFIER SYSTEM OPERATION................................................................ 704 No Steer................................................................................... 704 Steering Left.............................................................................. 706 Steering Right............................................................................. 708 No Steer, External Shock Load.............................................................. 710 Steering Pump.............................................................................. 712 High Pressure Filter....................................................................... 712 Accumulators............................................................................... 712 Low Precharge Warning Switch............................................................... 712 STEERING CONTROL UNIT INDEX............................................................................ 713 STEERING CONTROL UNIT.............................................................................. 715 GENERAL INFORMATION............................................................................ 715 Removal.................................................................................... 715 Installation............................................................................... 715 STEERING CONTROL UNIT REBUILD.................................................................. 717 Disassembly................................................................................ 717 Cleaning and Inspection.................................................................... 718 Assembly................................................................................... 720 STEERING/BRAKE PUMP............................................................................ 723 Removal.................................................................................... 723 Installation............................................................................... 723 Disassembly................................................................................ 725 Inspection of Parts........................................................................ 726 Assembly................................................................................... 726 STEERING CIRCUIT COMPONENT REPAIR INDEX................................................................ 729 STEERING CIRCUIT COMPONENT REPAIR.................................................................. 731 BLEED-DOWN MANIFOLD............................................................................ 731 Removal.................................................................................... 731 Installation............................................................................... 731 ACCUMULATOR.................................................................................... 732 Removal.................................................................................... 732 Installation............................................................................... 733 Disassembly................................................................................ 734 Cleaning and Inspection.................................................................... 734 Assembly................................................................................... 735 Leak Testing............................................................................... 736 STEERING ACCUMULATOR CHARGING.................................................................. 737 Temperature During Precharge............................................................... 740 ACCUMULATOR STORAGE............................................................................ 741 Installation............................................................................... 741 FLOW AMPLIFIER................................................................................. 742 Removal.................................................................................... 742 Installation............................................................................... 742 Disassembly................................................................................ 743 Assembly................................................................................... 746 STEERING CYLINDERS............................................................................. 747 Disassembly................................................................................ 747 Piston Seal and Bearing Installation....................................................... 747 Cylinder Assembly.......................................................................... 747 Test....................................................................................... 747 TROUBLESHOOTING CHART.............................................................................. 750 HOIST CIRCUIT INDEX.................................................................................... 755 HOIST CIRCUIT...................................................................................... 757 HOIST CIRCUIT OPERATION........................................................................ 757 COMPONENT DESCRIPTION.......................................................................... 758 Hydraulic Tank............................................................................. 758 Hydraulic Pump............................................................................. 758 High Pressure Filter....................................................................... 758 Hoist Valve................................................................................ 758 Hoist Pilot Valve.......................................................................... 759 Bleed-Down Manifold........................................................................ 760 Counterbalance Manifold.................................................................... 760 Hoist-Up Limit Solenoid.................................................................... 760 Pilot Operated Check Valve................................................................. 760 HOIST VALVE OPERATION.......................................................................... 762 Float Operation............................................................................ 762 Power Up Operation (Figure 7-6)............................................................ 764 Hold Operation (Figure 7-7)................................................................ 766 Power Down Operation (Figure 7-8).......................................................... 768 Float Operation (Figure 7-9)............................................................... 770 HOIST CIRCUIT COMPONENT REPAIR INDEX................................................................... 773 HOIST CIRCUIT COMPONENT REPAIR..................................................................... 775 HOIST VALVE.................................................................................... 775 Removal.................................................................................... 775 Installation............................................................................... 775 O-Ring Replacement......................................................................... 777 INLET SECTION.................................................................................. 778 Disassembly................................................................................ 778 Cleaning and Inspection.................................................................... 779 Assembly................................................................................... 779 REAR SPOOL SECTION (WORK PORTS)................................................................ 780 Disassembly................................................................................ 780 Cleaning and Inspection.................................................................... 782 Assembly................................................................................... 782 HOIST PILOT VALVE.............................................................................. 784 Removal.................................................................................... 784 Installation............................................................................... 784 Disassembly................................................................................ 785 Cleaning and Inspection.................................................................... 786 Assembly................................................................................... 786 HOIST UP LIMIT SOLENOID VALVE.................................................................. 787 HOIST CYLINDERS................................................................................ 788 Removal.................................................................................... 788 Installation............................................................................... 789 Disassembly................................................................................ 791 Cleaning and Inspection.................................................................... 792 SS1143 Tightening Tool - Assembly Drawing.................................................. 793 ASSEMBLY OF QUILL AND CYLINDER................................................................. 793 Quill Installation......................................................................... 793 Installation Of Check Balls And Plugs In Quill............................................. 794 Assembly of Cylinder....................................................................... 796 COUNTERBALANCE MANIFOLD........................................................................ 797 HIGH PRESSURE FILTERS INDEX............................................................................ 799 HYDRAULIC SYSTEM FILTERS........................................................................... 801 HOIST CIRCUIT FILTER........................................................................... 801 Filter Element Replacement................................................................. 801 Removal.................................................................................... 802 Installation............................................................................... 802 Indicator Switch........................................................................... 802 STEERING CIRCUIT FILTER........................................................................ 803 Filter Element Replacement................................................................. 803 Removal.................................................................................... 804 Installation............................................................................... 804 Indicator Switch........................................................................... 804 INDICATOR SWITCH............................................................................... 804 Test Procedure............................................................................. 804 HYDRAULIC CHECK-OUT PROCEDURE INDEX.................................................................... 807 HYDRAULIC CHECK-OUT PROCEDURE...................................................................... 809 INITIAL START UP AND FLUSHING.................................................................. 809 COMPONENT CHECKOUT AND ADJUSTMENT.............................................................. 811 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE.................................. 813 Counterbalance Valve Adjustment............................................................ 815 Manifold Assembly.......................................................................... 815 OIL CLEANLINESS CHECK.......................................................................... 815 Oil Sampling Location On Truck............................................................. 815 Oil Sampling Process and Cleanliness Criteria.............................................. 816 DISABLED TRUCK DUMPING PROCEDURE............................................................... 816 Hookup..................................................................................... 816 Raising the Body........................................................................... 816 Lowering the Body.......................................................................... 817 TROUBLESHOOTING CHART.......................................................................... 818 Hoist Pump................................................................................. 818 Steering Circuit........................................................................... 820 Brake/Steering Pump........................................................................ 822 Flow Amplifier - Refer to Figure 10-9...................................................... 824 SECTION M OPTIONS AND SPECIAL TOOLS INDEX.................................................................. 825 HEATER OPTIONS INDEX................................................................................... 827 ENGINE OIL HEATERS................................................................................. 829 GENERAL INFORMATION............................................................................ 829 TROUBLESHOOTING................................................................................ 829 HEATER ELEMENT................................................................................. 829 Removal.................................................................................... 829 Installation............................................................................... 830 ENGINE COOLANT HEATER.............................................................................. 831 GENERAL........................................................................................ 831 Maintenance................................................................................ 831 HEATING ELEMENT................................................................................ 831 Removal.................................................................................... 831 Installation............................................................................... 832 THERMOSTAT..................................................................................... 832 Removal.................................................................................... 832 Installation............................................................................... 832 HYDRAULIC OIL HEATERS.............................................................................. 833 GENERAL INFORMATION............................................................................ 833 TROUBLESHOOTING................................................................................ 833 HEATER ELEMENT................................................................................. 833 Removal.................................................................................... 833 Installation............................................................................... 834 SPECIAL TOOLS INDEX.................................................................................... 835 SPECIAL TOOLS...................................................................................... 837 RADIATOR SHUTTERS INDEX................................................................................ 845 RADIATOR SHUTTERS.................................................................................. 847 OPERATION...................................................................................... 847 Hydraulic Circuit.......................................................................... 847 Electrical Circuit:........................................................................ 848 MAINTENANCE AND REPAIR......................................................................... 848 TROUBLESHOOTING................................................................................ 849 Hydraulic Troubleshooting.................................................................. 852 Electrical Troubleshooting................................................................. 854 SECTION N OPERATOR'S CAB INDEX............................................................................. 855 TRUCK CAB INDEX........................................................................................ 857 TRUCK CAB.......................................................................................... 859 TRUCK CAB...................................................................................... 859 Description................................................................................ 859 Removal.................................................................................... 860 Installation............................................................................... 862 CAB DOOR....................................................................................... 862 Removal.................................................................................... 862 Installation............................................................................... 863 Door Adjustment............................................................................ 863 Door Jam Bolt Adjustment................................................................... 863 Door Handle Plunger Adjustment............................................................. 865 Replace Door Glass......................................................................... 866 Replace Door Window Regulator.............................................................. 870 Replace Door Handle or Latch Assembly...................................................... 870 Door and Door Hinge Seal Replacement....................................................... 871 Door Opening Seal Removal.................................................................. 871 Installation............................................................................... 871 GLASS REPLACEMENT.............................................................................. 872 Adhesive-Bonded Windows.................................................................... 872 Recommended Tools/Supplies................................................................. 872 Replacement Procedure...................................................................... 872 Windshield and Rear Glass.................................................................. 873 Removal.................................................................................... 873 Installation............................................................................... 874 Removal and Installation of Operator Seat...................................................... 875 Inspection................................................................................. 875 Removal.................................................................................... 875 Installation............................................................................... 875 Removal and Installation of Passenger Seat..................................................... 876 Removal.................................................................................... 876 Installation............................................................................... 876 CAB COMPONENTS INDEX................................................................................... 877 CAB COMPONENTS..................................................................................... 879 WINDSHIELD WIPERS.............................................................................. 879 WIPER MOTOR REPLACEMENT.................................................................... 879 Removal................................................................................ 879 Installation........................................................................... 879 WIPER ARM REPLACEMENT...................................................................... 879 Removal................................................................................ 879 Installation........................................................................... 880 WIPER LINKAGE REPLACEMENT.................................................................. 880 Removal................................................................................ 880 Installation........................................................................... 881 WINDSHIELD WASHER.......................................................................... 881 Operation.............................................................................. 881 Service................................................................................ 881 OPERATOR COMFORT INDEX................................................................................. 883 HEATER/AIR CONDITIONER............................................................................. 885 OPERATION...................................................................................... 885 Fan Speed Control Knob..................................................................... 885 Temperature Control Knob................................................................... 885 Air Flow Directional Knob.................................................................. 886 Heater/Air Conditioner Vents............................................................... 886 COMPONENTS..................................................................................... 886 Fuse and Circuit Breaker................................................................... 886 Relays..................................................................................... 886 Heater Core................................................................................ 887 Fan Motor And Speed Control................................................................ 887 Actuators.................................................................................. 887 Cab Air Filter............................................................................. 887 AIR CONDITIONING SYSTEM........................................................................ 889 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.................................................. 890 PRINCIPLES OF REFRIGERATION................................................................ 890 Air Conditioning....................................................................... 890 Refrigeration - The Act of Cooling..................................................... 891 The Refrigeration Cycle................................................................ 891 AIR CONDITIONER SYSTEM COMPONENTS.......................................................... 892 Compressor (Refrigerant Pump).......................................................... 892 Service Valves......................................................................... 892 Receiver-Drier......................................................................... 892 Condenser.............................................................................. 892 Expansion Block Valve.................................................................. 893 Accumulator............................................................................ 893 Evaporator............................................................................. 894 ELECTRICAL CIRCUIT......................................................................... 894 Thermostat............................................................................. 894 Compressor Clutch...................................................................... 895 Trinary™ Switch........................................................................ 895 SYSTEM SERVICING........................................................................... 897 SERVICE TOOLS AND EQUIPMENT................................................................ 898 Recovery/Recycle Station............................................................... 898 Leak Detector.......................................................................... 899 Service Valves......................................................................... 899 Vacuum Pump............................................................................ 899 Manifold Gauge Set..................................................................... 900 Low Side Gauge......................................................................... 900 High Side Gauge........................................................................ 900 Installing Manifold Gauge Set.......................................................... 901 Purging Air From Service Hoses......................................................... 901 SYSTEM PERFORMANCE TEST.................................................................... 902 SYSTEM OIL................................................................................. 903 Handling and Reusing RPAG Oil.......................................................... 903 Oil Quantity........................................................................... 903 Checking System Oil.................................................................... 903 REFRIGERANT................................................................................ 904 Recycled Refrigerant................................................................... 904 Reclaimed Refrigerant.................................................................. 904 Refrigerant Quantity................................................................... 905 R-134a Refrigerant Containers.......................................................... 905 SYSTEM LEAK TESTING........................................................................ 905 Electronic Leak Detector............................................................... 906 Tracer Dyes............................................................................ 906 Soap and Water......................................................................... 906 RECOVERING AND RECYCLING THE REFRIGERANT................................................... 906 Performing the Recovery Cycle.......................................................... 906 Performing the Recycling Procedure..................................................... 907 Evacuating and Charging the A/C System................................................. 907 SYSTEM REPAIR.............................................................................. 907 System Flushing........................................................................ 908 COMPONENT REPLACEMENT...................................................................... 908 Hoses and Fittings..................................................................... 908 Lines.................................................................................. 908 Expansion Valve........................................................................ 909 Receiver-Drier......................................................................... 909 Thermostat............................................................................. 909 Compressor............................................................................. 909 Accumulator............................................................................ 910 Clutch................................................................................. 910 Servicing the Compressor Clutch........................................................ 911 Pulley Removal......................................................................... 913 Clutch Coil Check...................................................................... 913 Pulley Installation.................................................................... 914 Clutch Assembly Installation........................................................... 914 EVACUATING THE SYSTEM...................................................................... 915 CHARGING THE A/C SYSTEM.................................................................... 917 AIR CONDITIONER DRIVE BELT................................................................. 917 Pulley Alignment....................................................................... 917 Belt Tension........................................................................... 918 TROUBLESHOOTING............................................................................ 919 Preliminary Checks..................................................................... 919 Diagnosis of Gauge Readings and System Performance..................................... 919 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS............................................. 920 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM........................................... 926 OPERATOR CONTROLS AND EQUIPMENT INDEX.................................................................. 927 OPERATOR CAB AND CONTROLS.......................................................................... 929 STEERING WHEEL AND CONTROLS.................................................................... 930 STEERING WHEEL............................................................................. 930 HORN BUTTON................................................................................ 930 TILT/TELESCOPE LEVER....................................................................... 930 M ULTI-FUNCTION TURN SIGNAL SWITCH......................................................... 930 Turn Signal Operation.................................................................. 930 High Beam Headlight Operation.......................................................... 930 Windshield Wiper Operation............................................................. 930 STEERING COLUMN............................................................................ 931 Removal................................................................................ 931 Inspection............................................................................. 931 Installation........................................................................... 932 PEDALS......................................................................................... 932 SERVICE BRAKE PEDAL........................................................................ 932 DYNAMIC RETARDER PEDAL..................................................................... 932 Optional - Dual Function/Single Pedal.................................................. 933 THROTTLE PEDAL............................................................................. 933 GRADE/SPEED WARNING CHART.................................................................. 933 OVERHEAD PANEL CONTROLS AND COMPONENTS......................................................... 934 RADIO SPEAKERS............................................................................. 934 WARNING ALARM BUZZER....................................................................... 934 CAB RADIO.................................................................................. 934 WARNING LIGHTS DIMMER CONTROL.............................................................. 934 WARNING/STATUS INDICATOR LIGHT PANEL....................................................... 934 AIR CLEANER VACUUM GAUGES.................................................................. 934 WINDSHIELD WIPERS.......................................................................... 934 TRUCK CONTROLS............................................................................. 935 F-N-R Selector Switch.................................................................. 935 Hoist Control Lever.................................................................... 936 CONSOLE SWITCHES AND CONTROLS.............................................................. 936 Ashtray................................................................................ 936 Cigarette Lighter...................................................................... 936 Left-Hand Window Control Switch........................................................ 936 Right-Hand Window Control Switch....................................................... 936 Engine Shutdown Switch................................................................. 936 Override Switch........................................................................ 936 Retard Speed Control (RSC) Switch...................................................... 937 Retard Speed Control (RSC) Dial........................................................ 937 Statex III Download Port............................................................... 938 Engine Diagnostic Port (CENSE)......................................................... 938 Modular Mining Port.................................................................... 938 Passenger Seat......................................................................... 938 Engine Diagnostic Connectors........................................................... 938 Engine Diagnostics Connector........................................................... 938 Data Store Button...................................................................... 938 PAYLOAD METER.............................................................................. 938 Payload Meter Download Connector....................................................... 938 OPERATOR SEAT.................................................................................. 939 Seat Belts................................................................................. 939 ADJUSTMENT................................................................................. 939 INSTRUMENT PANEL............................................................................... 940 CONTROL SYMBOLS............................................................................ 940 CONTROL SWITCHES AND GAUGES................................................................ 941 Key Switch............................................................................. 941 Engine Shutdown Switch With Timer Delay................................................ 942 Fog Light Switch....................................................................... 942 Ladder Light Switch.................................................................... 942 Backup Light Switch.................................................................... 942 Panel Illumination Lights.............................................................. 942 Cab Air Conditioner/Heater Vents....................................................... 942 Engine Cold Weather Starting Aid Switch................................................ 942 Rotating Beacon Light Switch........................................................... 942 Heated Mirror Switch................................................................... 942 Wheel Brake Lock Switch................................................................ 943 Parking Brake Switch................................................................... 943 Digital Tachometer..................................................................... 943 Right Turn Signal Indicator Light...................................................... 944 High Beam Headlight Indicator Light.................................................... 944 Left Turn Signal Indicator Light....................................................... 944 Digital Speedometer/Payload Meter Display.............................................. 944 Voltmeter Gauge........................................................................ 944 Engine Oil Pressure Gauge.............................................................. 944 Engine Water Temperature Gauge......................................................... 944 Fuel Gauge............................................................................. 944 Engine Hourmeter....................................................................... 944 Headlight Switch....................................................................... 945 Panel Illumination Lights Dimmer Rheostat.............................................. 945 Payload Meter Switch................................................................... 945 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL.................................................. 946 DESCRIPTION OF INDICATOR SYMBOLS........................................................... 946 INDICATOR LIGHT FUNCTIONS.................................................................. 947 A1. High Hydraulic Oil Temperature..................................................... 947 B1. Low Steering Pressure.............................................................. 947 C1. Low Accumulator Precharge Pressure................................................. 948 D1. Electric System Fault.............................................................. 948 E1. Low Brake Pressure................................................................. 948 A2. Low Hydraulic Tank Level........................................................... 948 B2. Automatic Lubrication System Pressure.............................................. 948 C2. Circuit Breaker Tripped............................................................ 948 D2. Hydraulic Oil Filter Monitor....................................................... 949 E2. Low Fuel........................................................................... 949 A3. Parking Brake...................................................................... 949 B3. Service Brake...................................................................... 949 C3. Body Up............................................................................ 949 D3. Dynamic Retarding.................................................................. 949 E3. Stop Engine........................................................................ 949 A4. Not Used........................................................................... 950 B4. Manual Backup Lights............................................................... 950 C4. Engine Shutdown Timer.............................................................. 950 D4. Retard Speed Control (RSC)......................................................... 950 E4. Check Engine....................................................................... 950 A5. Service Engine Indicator (AEM)..................................................... 950 B5. High Wheel Motor Temperature....................................................... 950 C5. Blower Fault....................................................................... 950 D5, E5, A6, B6, and C6. Not Used....................................................... 950 D6. Service Engine (CENSE)............................................................. 950 E6. Not Used........................................................................... 950 Komatsu Engines w/Centry™ Fuel Control................................................. 951 Hazard Warning Light Switch............................................................ 951 Lamp Test Switch/Centry™ Diagnostic Test Switch........................................ 951 VEHICLE HEALTH MONITORING SYSTEM (VHMS)........................................................ 951 BASIC PRECAUTIONS.......................................................................... 951 OPERATION.................................................................................. 951 INTERFACE MODULE........................................................................... 953 CENTRY™ FUEL SYSTEM DIAGNOSTICS................................................................ 954 GENERAL OPERATION.......................................................................... 954 DETERMINING FAULT CODES.................................................................... 954 EXITING THE DIAGNOSTICS MODE............................................................... 955 SECTION P LUBRICATION AND SERVICE INDEX.................................................................... 957 LUBRICATION AND SERVICE INDEX.......................................................................... 959 LUBRICATION AND SERVICE............................................................................ 961 GENERAL INFORMATION............................................................................ 961 HYDRAULIC TANK SERVICE......................................................................... 961 Adding Oil................................................................................. 961 COOLING SYSTEM................................................................................. 962 Radiator Filling Procedure................................................................. 962 RESERVE ENGINE OIL SYSTEM - (OPTIONAL)......................................................... 962 Reserve Oil Tank Filling Procedure (Remote Fill)........................................... 962 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS.................................................... 964 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)........................................ 965 50 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................................... 966 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................... 966 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................... 967 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)........................................ 968 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................... 969 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)........................................ 970 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 971 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 972 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 972 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 973 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................. 974 AUTOMATIC LUBRICATION SYSTEM INDEX..................................................................... 975 AUTOMATIC LUBRICATION SYSTEM....................................................................... 977 GENERAL DESCRIPTION............................................................................ 977 SYSTEM COMPONENTS.............................................................................. 978 Filter Assembly............................................................................ 978 Hydraulic Motor and Grease Pump............................................................ 978 Reservoir.................................................................................. 978 Fixed Pressure Reducing Valve.............................................................. 978 Flow Control Valve......................................................................... 978 Solenoid Valve............................................................................. 979 Vent Valve................................................................................. 979 24VDC Lubrication Cycle Timer.............................................................. 979 Time Delay Module.......................................................................... 979 Pump Cutoff Pressure Switch................................................................ 979 Unloader Valve............................................................................. 979 Pressure Switch............................................................................ 979 Manual Override Button..................................................................... 979 Injectors.................................................................................. 979 SYSTEM OPERATION............................................................................... 982 Normal Operation........................................................................... 982 Pressure Failure Detection Circuits........................................................ 983 GENERAL INSTRUCTIONS........................................................................... 984 LUBRICANT REQUIRED FOR SYSTEM.............................................................. 984 SYSTEM PRIMING............................................................................. 984 LUBRICANT PUMP............................................................................. 985 Pump Housing Oil Level................................................................. 985 Pump Pressure Control.................................................................. 985 FILTER AND RESERVOIR....................................................................... 985 Filter Assembly Element................................................................ 986 INJECTORS (SL-1 Series H).................................................................. 986 Injector Specifications................................................................ 986 Injector Adjustment.................................................................... 986 INJECTOR OPERATION................................................................................. 988 SYSTEM CHECKOUT................................................................................ 989 Lubrication Cycle Timer Check.............................................................. 989 Lubrication Cycle Timer Adjustment......................................................... 990 PREVENTIVE MAINTENANCE INSPECTION.............................................................. 990 10 Hour Lubrication System Inspection...................................................... 990 100 Hour Inspection........................................................................ 990 250 Hour Inspection........................................................................ 990 500 Hour Inspection........................................................................ 991 1000 Hour Inspection....................................................................... 991 PUMP REBUILD................................................................................... 992 Disassembly................................................................................ 992 Cleaning and Inspection.................................................................... 992 Assembly................................................................................... 994 VENT VALVE REBUILD............................................................................. 995 Disassembly and Assembly................................................................... 995 SYSTEM TROUBLESHOOTING CHART................................................................... 996 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX............................................................. 999 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1001 AXLE BOX.......................................................................................1001 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1002 ARMATURE AREA..................................................................................1002 AT TIRE CHANGE.................................................................................1002 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1003 GENERATOR/ALTERNATOR...........................................................................1003 GRID BLOWER MOTOR..............................................................................1003 CONTROL EQUIPMENT CHECKS.......................................................................1003 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1004 VEHICLE OPERATIONS TESTS.......................................................................1004 SECTION R SYSTEM SCHEMATICS INDEX..........................................................................1005
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