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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30620, A30522 – A30632) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30620, A30522 – A30632
- PUBLICATION NUMBER:CEBM025700
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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30620, A30522 – A30632) KOMATSU 730E
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30620, A30522 – A30632) KOMATSU 730E – PDF DOWNLOAD:
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TABLE OF CONTENTS:
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30620, A30522 – A30632) KOMATSU 730E
COVER ..................................................................................................... 0 FOREWORD................................................................................................... 5 TABLE OF CONTENTS.......................................................................................... 7 SECTION A GENERAL INFORMATION INDEX........................................................................ 9 MAJOR COMPONENT DESCRIPTION............................................................................ 11 SPECIFICATIONS..................................................................................... 13 Komatsu SSA16V159.............................................................................. 13 SECTION A3 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 SECTION A4 WARNINGS AND CAUTIONS..................................................................... 49 TORQUE TABLES AND CONVERSION CHARTS................................................................ 59 SECTION A5 TORQUE TABLES AND CONVERSION CHARTS ........................................................ 59 SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX.................................................. 69 STORAGE AND IDLE MACHINE PREPARATION............................................................... 71 SHORT TERM IDLE PERIODS........................................................................ 71 PREPARATION FOR STORAGE........................................................................ 72 REMOVAL FROM STORAGE........................................................................... 73 RECONDITIONING AN IDLE VEHICLE................................................................. 74 ENGINE OPERATION............................................................................... 77 After The Engine Has Started............................................................... 77 ENGINE STORAGE................................................................................. 78 Temporary Storage (30 Days Or Less)........................................................ 78 Extended Storage (More Than 30 Days)....................................................... 79 RESTORING AN ENGINE AFTER EXTENDED STORAGE..................................................... 80 ELECTRIC DRIVE TRUCKS.......................................................................... 81 Storing A Truck That Is Operational........................................................ 81 Storing A Truck That Is Not Operational.................................................... 82 Storing A Major Component.................................................................. 83 Periodic Inspections....................................................................... 83 Placing Equipment Into Service After Storage............................................... 83 SECTION B STRUCTURES INDEX................................................................................. 85 SECTION B2 STRUCTURAL COMPONENTS INDEX................................................................. 87 STRUCTURAL COMPONENTS.............................................................................. 89 LADDERS........................................................................................ 89 Removal.................................................................................... 89 Installation............................................................................... 89 GRILLE AND HOOD................................................................................ 90 Removal.................................................................................... 90 Installation............................................................................... 90 RIGHT-HAND DECK................................................................................ 90 Removal.................................................................................... 90 Installation............................................................................... 92 CENTER DECK.................................................................................... 92 LEFT-HAND DECK................................................................................. 93 Removal.................................................................................... 93 Installation............................................................................... 93 SECTION B3 DUMP BODY INDEX............................................................................. 95 DUMP BODY.......................................................................................... 97 Removal........................................................................................ 97 Installation................................................................................... 98 BODY SLING......................................................................................... 98 BODY PADS.......................................................................................... 99 BODY GUIDE......................................................................................... 99 Adjustment..................................................................................... 99 BODY POSITION INDICATOR............................................................................ 100 HOIST LIMIT SWITCH................................................................................. 100 ROCK EJECTORS...................................................................................... 100 Inspection..................................................................................... 100 SECTION B4 FUEL TANK INDEX............................................................................. 101 FUEL TANK.......................................................................................... 103 Removal........................................................................................ 103 Repair......................................................................................... 103 Cleaning....................................................................................... 103 Installation................................................................................... 104 FUEL GAUGE SENDER.................................................................................. 105 Removal........................................................................................ 105 Installation................................................................................... 105 LOW FUEL SENDER.................................................................................... 106 Removal........................................................................................ 106 Installation................................................................................... 106 TANK BREATHER VALVE................................................................................ 107 Removal........................................................................................ 107 Installation................................................................................... 107 Disassembly.................................................................................... 107 Assembly....................................................................................... 107 FUEL RECEIVER (WIGGINS QUICK FILL)................................................................. 108 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)............................................ 109 SECTION C ENGINE INDEX..................................................................................... 111 SECTION C2 POWER MODULE INDEX.......................................................................... 113 POWER MODULE....................................................................................... 115 GENERAL INFORMATION............................................................................ 115 POWER MODULE SERVICE........................................................................... 116 Removal.................................................................................... 116 Installation............................................................................... 120 SECTION C3 COOLING SYSTEM INDEX........................................................................ 123 COOLING SYSTEM..................................................................................... 125 RADIATOR....................................................................................... 125 Removal.................................................................................... 125 Service.................................................................................... 126 Installation............................................................................... 126 RADIATOR FILL PROCEDURE........................................................................ 127 RADIATOR REPAIR................................................................................ 127 Internal Inspection........................................................................ 127 External Cleaning.......................................................................... 128 Disassembly................................................................................ 128 Cleaning and Inspection.................................................................... 129 Assembly................................................................................... 129 Additional Service Information............................................................. 131 PRESSURE TESTING............................................................................... 131 COOLANT SYSTEM TROUBLESHOOTING................................................................. 131 SECTION C4 POWER TRAIN INDEX........................................................................... 133 POWER TRAIN........................................................................................ 135 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.................................................. 135 General Information........................................................................ 135 Removal.................................................................................... 135 ALTERNATOR INSTALLATION........................................................................ 137 Engine/Alternator Mating................................................................... 137 Alternator Measurement..................................................................... 137 Engine End Play Measurement................................................................ 138 Determining Shim Requirements.............................................................. 139 Installing Alternator On Engine............................................................ 140 ENGINE......................................................................................... 141 Removal.................................................................................... 141 Installation............................................................................... 141 SECTION C5 AIR CLEANERS INDEX.......................................................................... 143 AIR CLEANERS....................................................................................... 145 OPERATION...................................................................................... 145 SERVICING THE AIR CLEANERS..................................................................... 145 Replacing The Elements..................................................................... 146 AIR CLEANER ASSEMBLY CLEANING.................................................................. 147 Primary Element Cleaning................................................................... 147 Precleaner Section Cleaning................................................................ 149 AIR INTAKE TROUBLESHOOTING..................................................................... 150 SECTION C7 FAN DRIVE CLUTCH INDEX...................................................................... 151 FAN DRIVE CLUTCH................................................................................... 152 COMPONENTS..................................................................................... 152 Input...................................................................................... 152 Output..................................................................................... 152 Stationary Components...................................................................... 153 OPERATIONAL MODES.............................................................................. 154 Fully Engaged.............................................................................. 154 Modulated Variable Speed................................................................... 154 Fully Released............................................................................. 155 Lubricating and Cooling Oil................................................................ 156 MAINTENANCE.................................................................................... 157 TROUBLESHOOTING................................................................................ 158 Preliminary Checks......................................................................... 158 FIELD CHECK DIAGNOSIS.......................................................................... 159 Preliminary Checks - Engine Off............................................................ 159 Check Clutch Release....................................................................... 159 Check Clutch Lock-up....................................................................... 160 Overheating................................................................................ 160 Thermal Sensor and Solenoid Valve.......................................................... 161 On Truck Test.............................................................................. 161 Off Truck Test............................................................................. 161 FAN CLUTCH DISASSEMBLY INSTRUCTIONS................................................................ 166 REASSEMBLY OF THE FAN CLUTCH....................................................................... 173 INSPECTION OF PARTS................................................................................ 184 REBUILD TOOLS...................................................................................... 188 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX................................................... 189 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX.......................................................... 191 24VDC ELECTRIC SUPPLY SYSTEM....................................................................... 193 ELECTRICAL SYSTEM DESCRIPTION.................................................................. 193 BATTERIES...................................................................................... 193 Maintenance and Service.................................................................... 193 Troubleshooting............................................................................ 193 BATTERY CHARGING ALTERNATOR.................................................................... 195 24VDC ELECTRIC START SYSTEM........................................................................ 195 CRANKING MOTORS................................................................................ 195 Removal.................................................................................... 195 Installation............................................................................... 196 CRANKING MOTOR TROUBLESHOOTING................................................................. 196 Preliminary Inspection..................................................................... 197 No-Load Test............................................................................... 197 Interpreting Results of Tests.............................................................. 197 Disassembly................................................................................ 198 Cleaning and Inspection.................................................................... 198 Armature Servicing......................................................................... 199 Field Coil Checks.......................................................................... 201 Field Coil Removal......................................................................... 201 Solenoid Checks............................................................................ 201 Test....................................................................................... 201 Assembly................................................................................... 203 Pinion Clearance........................................................................... 204 MAGNETIC SWITCH................................................................................ 204 Coil Test.................................................................................. 204 Electric Start System Wiring Diagrams...................................................... 204 ENGINE PRELUB SYSTEM............................................................................... 205 OPERATION...................................................................................... 205 Pressure Switch............................................................................ 205 Suction Line............................................................................... 205 Outlet Line................................................................................ 205 Check Valve................................................................................ 205 Solenoid Timer............................................................................. 205 TROUBLESHOOTING PRELUB STARTER CIRCUIT............................................................. 207 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX.................................................... 211 24VDC ELECTRICAL SYSTEM COMPONENTS................................................................. 213 PASSENGER SEAT BASE COMPARTMENT................................................................ 213 COMPONENTS..................................................................................... 213 Taillight Resistor Diode Assemblies........................................................ 213 Inclinometer............................................................................... 213 Lubrication System Timer................................................................... 213 Three Minute Idle Timer Components......................................................... 213 Three Minute Idle Timer.................................................................... 215 Idle Timer Relay........................................................................... 215 Three Minute Idle Contactor................................................................ 215 Three Minute Idle Circuit Test............................................................. 215 Data Store Button.......................................................................... 215 Komatsu Engine Diagnostic Connector (Centry)............................................... 215 Komatsu Engine Diagnostic Port (CENSE)..................................................... 215 STATEX III Propulsion System Diagnostic Connector.......................................... 215 Modular Mining Port (Optional)............................................................. 215 Alarm Indicating Device (AID) System....................................................... 216 Diode Matrix (Without Sound)............................................................... 216 Diode Matrix (With Sound).................................................................. 217 Hot Switch Inverter........................................................................ 217 Hot Switch Inverter Card (Slot 4) (Not Used)............................................... 217 Temperature................................................................................ 217 Oil Level.................................................................................. 217 Temperature and Latch...................................................................... 217 Coolant Level/Flasher...................................................................... 218 Lamp Test.................................................................................. 218 BATTERY EQUALIZER BOX.......................................................................... 218 Troubleshooting............................................................................ 218 BODY POSITION SWITCHES......................................................................... 220 Proximity Switch Operation................................................................. 220 Body-Up Switch Adjustment.................................................................. 221 Hoist Limit Switch Adjustment.............................................................. 221 24-VOLT RELAY AND DIODE BOARDS................................................................. 223 RELAY BOARDS................................................................................... 224 Description................................................................................ 224 SERVICE........................................................................................ 224 To Replace A Relay:........................................................................ 224 To Replace A Circuit Breaker:.............................................................. 224 To Replace A Circuit Panel Card............................................................ 225 Relay Board Components..................................................................... 225 Installing Additional Circuits............................................................. 226 DIODE BOARD 1.............................................................................. 227 Diode Testing.............................................................................. 227 CIRCUIT BREAKERS................................................................................... 229 SECTION D11 KOMTRAX Plus COMPONENTS INDEX.............................................................. 231 VEHICLE HEALTH MONITORING SYSTEM (KOMTRAX Plus).................................................... 233 KOMTRAX Plus BASIC FEATURES.................................................................... 233 Gather Data................................................................................ 233 Convert and Record Data.................................................................... 234 Communicate Data to Off-Board Systems...................................................... 234 USING THE KOMTRAX Plus SYSTEM.................................................................. 235 Basic Precautions.......................................................................... 235 Turning the KOMTRAX Plus System On......................................................... 235 Normal KOMTRAX Plus Operation.............................................................. 236 Turning the KOMTRAX Plus System Off........................................................ 236 Downloading From the KOMTRAX Plus Controller............................................... 236 KOMTRAX Plus DATA ITEMS........................................................................ 237 Fault Codes................................................................................ 237 Machine History............................................................................ 237 KOMTRAX Plus History....................................................................... 238 Snapshots.................................................................................. 238 Manual Snapshots........................................................................... 238 Trends..................................................................................... 238 Histogram (Load Map) Data.................................................................. 240 Haul Cycle Data............................................................................ 241 Alarm and Snapshot Triggers................................................................ 242 Satellite Features......................................................................... 244 KOMTRAX Plus DIAGNOSTIC FEATURES............................................................... 244 Fault History.............................................................................. 244 KOMTRAX Plus LED Digits.................................................................... 244 Light (10) PLM III communication........................................................... 244 Light (11) OrbComm......................................................................... 244 KOMTRAX Plus COMPONENTS............................................................................ 245 KOMTRAX Plus CONTROLLER........................................................................ 245 Removal.................................................................................... 246 Installation............................................................................... 246 OrbComm Controller......................................................................... 247 Removal.................................................................................... 247 Installation............................................................................... 248 INTERFACE MODULE............................................................................... 248 Inputs..................................................................................... 249 Outputs.................................................................................... 249 Removal.................................................................................... 249 Installation............................................................................... 249 COMPONENT LOCATION............................................................................. 250 Circuit Breakers........................................................................... 250 Temperature Sensors........................................................................ 251 Pressure Sensors........................................................................... 252 SECTION D12 KOMTRAX Plus SOFTWARE INDEX................................................................ 253 KOMTRAX Plus SOFTWARE.............................................................................. 255 Necessary Software............................................................................. 255 Necessary Tools................................................................................ 256 KOMTRAX Plus TOOL BOX INSTALLATION............................................................. 256 KOMTRAX Plus SETTING TOOL INSTALLATION......................................................... 257 KOMTRAX Plus INITIALIZATION PROCEDURE.......................................................... 257 Preliminary Checks......................................................................... 257 Initialization Steps....................................................................... 257 Select Operation........................................................................... 258 KOMTRAX Plus Setting Function.............................................................. 258 Machine Information Setting(1)............................................................. 258 Machine Information Setting(2)............................................................. 258 Date and Time Setting...................................................................... 259 GCC Setting................................................................................ 259 Setting Summary............................................................................ 259 KOMTRAX Plus SNAPSHOT PROCEDURE................................................................ 260 KOMTRAX Plus DOWNLOAD.......................................................................... 260 KOMTRAX Plus FTP UPLOAD........................................................................ 261 LOCATION OF DOWNLOAD FILES..................................................................... 262 INSTALLING FLASHBURN PROGRAM................................................................... 263 INSTALLING APPLICATION CODE INTO INTERFACE MODULE.............................................. 263 INSTALLING REALTIME MONITOR SOFTWARE PROGRAM................................................... 264 WHEN REPLACING A KOMTRAX Plus CONTROLLER....................................................... 264 To Set: Date and time, satellite, payload meter............................................ 266 Review Setting Information................................................................. 268 SECTION D13 KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING INDEX............................................ 269 KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING.......................................................... 272 KOMTRAX Plus CHECKOUT PROCEDURE................................................................ 272 General.................................................................................... 272 Structure and Purpose...................................................................... 273 Necessary Equipment:....................................................................... 273 KOMTRAX Plus SYSTEM CHECKOUT................................................................... 273 Preliminary................................................................................ 273 Checking Inputs To The Interface Module.................................................... 274 For 930E & 960E trucks only:............................................................... 276 For 830E trucks only:...................................................................... 276 Checking Outputs From The Interface Module................................................. 277 For 830E only:............................................................................. 277 For 930E & 960E only:...................................................................... 277 KOMTRAX Plus CONTROLLER CHECKOUT............................................................... 277 TROUBLESHOOTING................................................................................ 278 Communications Networks.................................................................... 278 Coaxial Cable.............................................................................. 278 KOMTRAX Plus COMPONENTS........................................................................ 279 KOMTRAX Plus Controller.................................................................... 279 OrbComm Controller......................................................................... 280 Interface Module........................................................................... 280 FAULT CODES.................................................................................... 281 Fault History.............................................................................. 281 KOMTRAX Plus LED Display Fault Codes....................................................... 282 Chassis Fault Codes........................................................................ 283 Engine Fault Codes......................................................................... 287 FAULT TREE ANALYSIS............................................................................ 293 Unable to connect to KOMTRAX Plus from laptop PC........................................... 293 Flashing Error Code N4-23 (PLM III Communications Fault)................................... 294 Flashing Error Code N4-22 (Engine Communications Fault).................................... 295 No Data Received By WebCARE................................................................ 296 Coaxial Cable Troubleshooting.............................................................. 297 SECTION D14 KOMTRAX PLUS FORMS INDEX................................................................... 299 KOMTRAX PLUS FORMS................................................................................. 301 KOMTRAX PLUS INITIALIZATION CHECK LIST......................................................... 301 KOMTRAX PLUS DATA DOWNLOAD..................................................................... 302 KOMTRAX PLUS INITIALIZATION CHECK LIST......................................................... 303 KOMTRAX PLUS INITIALIZATION FORM............................................................... 305 SECTION D35 PAYLOAD METER III INDEX.................................................................... 307 OPERATION SECTION.................................................................................. 312 Introduction................................................................................... 312 Data Summary............................................................................... 312 Data Gathering............................................................................. 312 COMPONENT DESCRIPTION.......................................................................... 313 System Diagram............................................................................. 313 Suspension Pressure Sensors................................................................ 313 Inclinometer............................................................................... 313 Operator Display........................................................................... 313 Operator Switch............................................................................ 314 Speed Input................................................................................ 314 Body-Up Switch............................................................................. 314 Brake Lock Switch.......................................................................... 314 Payload Meter.............................................................................. 314 Communications Ports....................................................................... 314 Key Switch Input........................................................................... 315 Payload Meter Power........................................................................ 315 Load Lights................................................................................ 315 Wiring and Termination..................................................................... 316 TCI Outputs................................................................................ 316 OPERATOR’S DISPLAY AND SWITCH.................................................................. 317 Reading the Speedometer.................................................................... 317 Reading the Load Display................................................................... 317 Using the Operator ID...................................................................... 317 Using the Load and Ton Counter............................................................. 317 Total Ton Counter.......................................................................... 317 Total Load Counter......................................................................... 318 Clearing the Counters...................................................................... 318 Viewing Live Sensor Data................................................................... 318 Other Display Messages..................................................................... 318 PAYLOAD OPERATION & CALCULATION................................................................ 319 Description of Haul Cycle States........................................................... 319 Haul Cycle Description..................................................................... 319 Load Calculation........................................................................... 320 Carry Back................................................................................. 320 Measurement Accuracy....................................................................... 320 SOURCES FOR PAYLOAD ERROR...................................................................... 320 Payload Error.............................................................................. 320 Loading Conditions......................................................................... 321 Pressure Sensors........................................................................... 321 Swingloads................................................................................. 321 Speed and Distance......................................................................... 321 HAUL CYCLE DATA................................................................................ 321 Haul Cycle Warning Flags................................................................... 323 Frame Torque Data.......................................................................... 324 Sprung Weight Data......................................................................... 324 Maximum Speed Data......................................................................... 324 Alarm Records.............................................................................. 324 Fault Code Data............................................................................ 325 PC SOFTWARE OVERVIEW........................................................................... 326 System Configuration....................................................................... 326 Installing the PLMIII Software............................................................. 326 DOWNLOADING DATA............................................................................... 327 PLM III SYSTEM CONFIGURATION................................................................... 328 Starting Communications.................................................................... 328 Displayed Payload Units.................................................................... 328 Time Units................................................................................. 328 Connection Menu............................................................................ 328 Connecting to the Payload Meter............................................................ 329 Configure the Payload Meter................................................................ 329 Setting the Date and Time.................................................................. 329 Setting the Truck Type..................................................................... 330 Setting the Gauge Display Units............................................................ 330 Setting the Frame Serial Number............................................................ 330 Setting the Truck Number................................................................... 330 Setting the Komatsu Distributor............................................................ 330 Setting the Komatsu Customer............................................................... 330 Setting the Overload Speed Limit Function.................................................. 331 Clean Truck Tare........................................................................... 332 Inclinometer Calibration................................................................... 332 DATA ANALYSIS.................................................................................. 333 Creating a Query........................................................................... 333 Sorting on Truck Unit Number............................................................... 333 Sorting on Truck Type...................................................................... 333 Sorting on Date Range...................................................................... 334 Sorting on Time Range...................................................................... 334 Payload Detail Screen...................................................................... 335 Creating Reports........................................................................... 335 Summary - one page report.................................................................. 336 Detailed - multi-page report............................................................... 336 Creating Graphs............................................................................ 337 Exporting Data............................................................................. 337 CSV Export................................................................................. 337 Compressed................................................................................. 338 Importing Data............................................................................. 339 Deleting Haul Cycle Records................................................................ 339 Viewing Alarms............................................................................. 340 Deleting Alarm Records..................................................................... 340 TROUBLESHOOTING SECTION............................................................................ 341 TROUBLESHOOTING................................................................................ 341 Viewing Active Alarms...................................................................... 341 Real-Time Data Display..................................................................... 341 Testing the Payload Lights................................................................. 341 Creating Log Files of Inputs............................................................... 342 Daily Inspections.......................................................................... 342 Periodic Maintenance....................................................................... 342 Abnormal Displays at Power-Up.............................................................. 343 No Payload Display When Key Switch is Turned ON............................................ 344 No Display on Speedometer.................................................................. 345 No Display on Operator Display............................................................. 345 No Communications With PC.................................................................. 346 Load Lights Don’t Light During Loading..................................................... 347 Load Lights Remain ON...................................................................... 348 Load Lights Remain ON During Dumping....................................................... 348 Display Doesn't Clear When The Load Is Dumped.............................................. 348 Calibration Problems....................................................................... 349 Alarm 1 - Left Front Pressure High......................................................... 350 Alarm 2 - Left Front Pressure Low.......................................................... 350 Troubleshoot Wiring to Left Front Suspension............................................... 350 Alarm 3 - Right Front Pressure High........................................................ 351 Alarm 4 - Right Front Pressure Low......................................................... 351 Troubleshoot Wiring to Right Front Suspension.............................................. 351 Alarm 5 -Left Rear Pressure High........................................................... 352 Alarm 6 - Left Rear Pressure Low........................................................... 352 Troubleshoot Wiring to Left Rear Suspension................................................ 352 Alarm 7 - Right Rear Pressure High......................................................... 353 Alarm 8 - Right Rear Pressure Low.......................................................... 353 Troubleshoot Wiring to Right Rear Suspension............................................... 353 Alarm 9 - Inclinometer High................................................................ 354 Alarm 10 - Inclinometer Low................................................................ 354 Troubleshoot Inclinometer Wiring........................................................... 354 Alarm 13 - Body Up Input Failure........................................................... 355 Alarm 16 - Memory Write Failure............................................................ 356 Alarm 17 - Memory Read Failure............................................................. 356 Alarm 18................................................................................... 356 Alarm 19................................................................................... 356 Alarm 22................................................................................... 356 Operator Switch Doesn't Work............................................................... 357 Alarm 26 - User Switch Fault - SELECT...................................................... 357 Alarm 27 - User Switch Fault - SET......................................................... 357 Connector Map.............................................................................. 358 Connectors................................................................................. 359 PLMIII CHECK OUT PROCEDURE..................................................................... 360 General Description........................................................................ 360 Tools Required............................................................................. 360 Checkout Procedure......................................................................... 360 PLMIII CHECKOUT PROCEDURE CONFIRMATION..................................................... 364 Flashburn Programming.................................................................. 364 Confirmation Checklist................................................................. 366 SECTION E ELECTRICAL PROPULSION INDEX...................................................................... 367 SECTION E2 ELECTRICAL PROPULSION COMPONENTS INDEX...................................................... 369 ELECTRICAL PROPULSION COMPONENTS................................................................... 373 GENERAL SYSTEM DESCRIPTION..................................................................... 373 CONTROL SYSTEM................................................................................. 373 System Operation........................................................................... 374 FL275 Panel................................................................................ 375 CARD REPLACEMENT............................................................................... 376 Removal.................................................................................... 376 Installation............................................................................... 376 Card Repair................................................................................ 376 Panel Wiring............................................................................... 376 COMPUTER DESCRIPTION........................................................................... 377 Microprocessor............................................................................. 377 Download Capability........................................................................ 377 SOFTWARE....................................................................................... 377 Base Monitor Program....................................................................... 377 Runtime Monitor Program - OBJ Running Code................................................. 377 Configuration Software - CFG............................................................... 378 PTU - Portable Test Unit Code.............................................................. 378 System Regulation.......................................................................... 378 Propulsion................................................................................. 379 Retarding.................................................................................. 379 TWO-DIGIT DISPLAY PANEL........................................................................ 380 The Coded Number........................................................................... 380 Events..................................................................................... 380 Frames..................................................................................... 381 Windows.................................................................................... 381 System Categories.......................................................................... 381 Limits On Resetting Faults................................................................. 381 NA Faults.................................................................................. 382 Event Sequence............................................................................. 382 Resetting Events........................................................................... 382 Event Descriptions......................................................................... 382 Subcode Descriptions....................................................................... 382 2-DIGIT DISPLAY PANEL SUBCODES................................................................. 390 PORTABLE TEST UNIT (PTU)........................................................................... 393 DESCRIPTION.................................................................................... 393 Operational Hints.......................................................................... 393 SOFTWARE INSTALLATION PREPARATION.............................................................. 394 HARD DISK SPACE REQUIREMENTS................................................................... 394 SOFTWARE INSTALLATION ON PTU................................................................... 394 PTU/Truck Communication Problems........................................................... 395 THE MAIN MENU.................................................................................. 396 Quit Menu.................................................................................. 396 PTU Talk To Truck.......................................................................... 396 View PTU Saved Files....................................................................... 396 List Stat Data Files....................................................................... 396 Truck Setup (CFG).......................................................................... 396 Select Truck Setup......................................................................... 396 Update CFG Version......................................................................... 396 Change PTU Password........................................................................ 396 CONFIGURATION (CFG) FILE CONVERSION............................................................ 398 Conversion Procedure....................................................................... 398 Convert Old CFG files for New software..................................................... 399 STATEX CONFIGURATION FILES..................................................................... 402 0) Source Directory: . . .................................................................. 402 1) Select A Truck Configuration . . ....................................................... 403 2) View Truck Configuration: Data Curves . . .............................................. 404 3) Change/View Serial and Model Numbers . . ............................................... 405 4) View Options . . ....................................................................... 405 5) Change/View Truck Specifics . . ........................................................ 407 6) Change/View Overspeeds . . ............................................................. 409 7) Save a Truck Configuration, filename: . . .............................................. 410 8) Save Directory: . . .................................................................... 411 CHANGE PTU PASSWORD............................................................................ 412 PROGRAMMING THE TRUCK.......................................................................... 413 Connect PTU to the Truck................................................................... 413 Select Configuration File.................................................................. 413 Activate The PTU Mode...................................................................... 413 Check Object Code Version.................................................................. 414 Download Configuration Files............................................................... 415 Date And Time.............................................................................. 416 Event Data................................................................................. 417 Statistical Data........................................................................... 419 View Counters.............................................................................. 419 View Profiles.............................................................................. 419 Upload Statistical Data To A File.......................................................... 419 Statistical Data Codes - Counters.......................................................... 420 STATISTICAL DATA CODES - COUNTERS.............................................................. 421 STATISTICAL DATA CODES - PROFILES.............................................................. 426 TRUCK SPECIFIC INFORMATION..................................................................... 430 Temporary Truck Settings................................................................... 431 MISCELLANEOUS FEATURES......................................................................... 432 Saving Data................................................................................ 432 PTU Abbreviations.......................................................................... 433 Other Menu Selections...................................................................... 433 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..................................................... 434 ALTERNATOR..................................................................................... 434 ELECTRIC WHEEL MOTORS.......................................................................... 434 RETARDING GRIDS................................................................................ 434 ELECTRONIC ACCELERATOR AND RETARD PEDALS....................................................... 434 Removal.................................................................................... 434 Installation............................................................................... 434 Disassembly................................................................................ 435 Reassembly................................................................................. 435 COOLING BLOWER WARNING SYSTEM.................................................................. 435 Operation.................................................................................. 435 Test....................................................................................... 435 Removal.................................................................................... 436 Installation............................................................................... 436 ELECTRICAL CONTROL CABINET......................................................................... 437 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS............................................. 442 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III................................................. 443 SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX....................................... 445 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.................................................... 449 GENERAL INFORMATION............................................................................ 449 COMMUNICATIONS PORT CHECK...................................................................... 450 PTU Hookup................................................................................. 450 4.0 SEQUENCE TESTS - (ENGINE NOT ON)............................................................... 451 Preparation and Setup.......................................................................... 451 CONTROL SYSTEM SELF-TEST....................................................................... 452 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT....................................................... 452 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT......................................................... 453 PTU Setup.................................................................................. 453 4.3 REVERSER AND PROPULSION CONTACTORS CHECK................................................... 454 4.4 NOT USED................................................................................... 455 4.5 RETARD CONTACTORS OPERATION CHECK.......................................................... 455 4.6 GROUND FAULT SENSING CHECK................................................................. 455 4.7 GROUND FAULT IN RETARD OPERATION CHECK..................................................... 456 4.8 OVERRIDE OPERATION CHECK................................................................... 456 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK.......................................................... 457 4.10 OVERSPEED RETARD OPERATION CHECK.......................................................... 457 4.11 HOIST INTERLOCK OPERATION CHECK........................................................... 458 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.................................................. 458 Return to Main Menu........................................................................ 458 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL........................................... 459 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.............................................. 459 5.2 DIGITAL INPUT CHECKS....................................................................... 460 5.3 DIGITAL OUTPUT CHECKS...................................................................... 461 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL................................................... 465 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU................................................... 465 6.2 ANALOG INPUT CHECKS........................................................................ 466 6.3 FREQUENCY INPUT CHECKS..................................................................... 470 Return to Main Menu........................................................................ 471 7.0 SPEED EVENT CHECKS............................................................................. 471 Preparation and Setup.......................................................................... 471 Setup PTU...................................................................................... 471 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK.................................... 472 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK......................... 472 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK........................ 472 7.4 OTHER SPEED EVENTS CHECKS.................................................................. 472 Return to Main Menu........................................................................ 472 8.0 RETARD SPEED CONTROL SYSTEM CHECK.............................................................. 473 Preparation and Setup.......................................................................... 473 Setup PTU...................................................................................... 473 8.1 OVERSPEED PICKUP AND DROPOUT CHECK......................................................... 473 8.2 RETARD POT MAXIMUM SETTING CHECK........................................................... 473 8.3 RETARD POT MINIMUM SETTING CHECK........................................................... 473 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL......................................... 474 Return to Main Menu........................................................................ 474 9.0 LOAD TEST USING TRUCK RETARD GRIDS............................................................. 474 Setup and Preparation.......................................................................... 474 PTU Setup...................................................................................... 474 9.1 LOAD TEST.................................................................................. 475 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING........................................................ 475 Setup PTU...................................................................................... 475 10.1 RETARD CHECK.............................................................................. 476 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT................................................... 477 11.1 BRAKE SYSTEM INTERLOCKS CHECK............................................................. 477 Preparation................................................................................ 477 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT.................................................... 477 11.3 SYNC TRANSFORMER CHECKOUT................................................................. 478 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT................................................ 478 11.5 BATTERY BOOST ADJUSTMENT.................................................................. 478 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST............................................... 478 11.7 MOTOR ROTATION TEST....................................................................... 479 11.8 GROUND FAULT CHECKS....................................................................... 479 12.0 MISCELLANEOUS CHARTS.......................................................................... 480 12.1 WHEEL MOTOR GEAR RATIOS................................................................... 480 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS............................................................ 481 12.3 ENGINE.................................................................................... 482 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX............................................................ 483 SECTION G2 TIRES AND RIMS INDEX........................................................................ 485 TIRES AND RIMS..................................................................................... 487 GENERAL INFORMATION............................................................................ 487 TIRES.......................................................................................... 487 Handling Tires............................................................................. 487 Tire Maintenance........................................................................... 488 Storing Tires After Removal................................................................ 488 FRONT TIRES AND RIMS........................................................................... 489 Removal.................................................................................... 489 Installation............................................................................... 490 REAR TIRES AND RIMS............................................................................ 491 Removal.................................................................................... 491 Installation............................................................................... 492 RIM........................................................................................ 493 Tire Removal............................................................................... 493 RIM AND TIRE PREPARATION....................................................................... 494 LUBRICANTS..................................................................................... 494 TIRE INSTALLATION.............................................................................. 495 SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX........................................................... 497 FRONT WHEEL HUB AND SPINDLE........................................................................ 499 WHEEL HUB AND SPINDLE ASSEMBLY................................................................. 499 Removal.................................................................................... 499 Installation............................................................................... 501 Disassembly................................................................................ 502 Cleaning and Inspection.................................................................... 503 Assembly................................................................................... 503 Wheel Bearing Adjustment (Spindle Vertical)................................................ 506 Wheel Bearing Adjustment (Tire Mounted).................................................... 507 Spindle Removal Procedure (Optional) (off of the truck).................................... 510 STEERING CYLINDERS AND TIE ROD................................................................. 512 Spherical Bearing Wear Limits.............................................................. 512 Removal.................................................................................... 513 Installation............................................................................... 515 Bearing Replacement........................................................................ 515 TOE-IN ADJUSTMENT.............................................................................. 516 SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX......................................................... 517 REAR AXLE HOUSING.................................................................................. 519 PIVOT PIN...................................................................................... 519 Removal.................................................................................... 519 Installation............................................................................... 520 PIVOT EYE BEARING.............................................................................. 520 Disassembly................................................................................ 520 Assembly................................................................................... 521 PIVOT EYE REPAIR............................................................................... 521 Removal.................................................................................... 521 Disassembly................................................................................ 521 Bushing (New).............................................................................. 521 Pivot Eye Bore (New)....................................................................... 521 Assembly................................................................................... 521 Installation............................................................................... 522 ANTI-SWAY BAR.................................................................................. 522 Removal.................................................................................... 522 Installation............................................................................... 522 Disassembly................................................................................ 523 Cleaning and Inspection.................................................................... 523 Assembly................................................................................... 523 SECTION G5 REAR AXLE HOUSING INDEX..................................................................... 525 REAR AXLE HOUSING.................................................................................. 527 REAR AXLE HOUSING.............................................................................. 527 Removal.................................................................................... 527 Installation............................................................................... 527 WHEEL MOTOR.................................................................................... 527 Removal.................................................................................... 527 Cleaning and Inspection.................................................................... 528 Installation............................................................................... 528 Maximum Cap Screw Usage.................................................................... 528 SECTION H SUSPENSIONS INDEX................................................................................ 531 SECTION H2 FRONT SUSPENSION INDEX...................................................................... 533 FRONT SUSPENSION................................................................................... 535 Removal........................................................................................ 535 Installation................................................................................... 537 Angle Advance Tightening Procedure............................................................. 538 Disassembly.................................................................................... 539 Cleaning and Inspection........................................................................ 540 Assembly (Bearing Only)........................................................................ 540 Suspension Assembly (Complete)................................................................. 540 SUSPENSION PRESSURE TEST....................................................................... 542 SECTION H3 REAR SUSPENSIONS INDEX...................................................................... 545 REAR SUSPENSIONS................................................................................... 547 Removal........................................................................................ 548 Installation................................................................................... 550 Disassembly.................................................................................... 550 Cleaning and Inspection........................................................................ 551 Assembly....................................................................................... 551 SUSPENSION PRESSURE TEST....................................................................... 553 SECTION H4 OILING AND CHARGING PROCEDURES INDEX........................................................ 555 OILING AND CHARGING PROCEDURE...................................................................... 557 GENERAL........................................................................................ 557 EQUIPMENT LIST................................................................................. 557 Hydrair® Charging Kit...................................................................... 557 Installation of Charging Kit............................................................... 557 Removal of Charging Kit.................................................................... 558 Support Blocks For Oiling and Charging Dimensions.......................................... 558 FRONT SUSPENSION............................................................................... 559 Front Suspension Oiling.................................................................... 559 Front Suspension Nitrogen Charging......................................................... 560 REAR SUSPENSION................................................................................ 562 Rear Suspension Oiling..................................................................... 562 Rear Suspension Nitrogen Charging.......................................................... 564 OIL AND NITROGEN SPECIFICATIONS CHART.............................................................. 565 SECTION J BRAKE CIRCUIT INDEX.............................................................................. 567 SECTION J2 BRAKE CIRCUIT INDEX......................................................................... 569 BRAKE CIRCUIT...................................................................................... 571 GENERAL DESCRIPTION............................................................................ 571 SERVICE BRAKE CIRCUIT.......................................................................... 571 SECONDARY BRAKING AND AUTOMATIC APPLY.......................................................... 573 PARKING BRAKE CIRCUIT.......................................................................... 573 Normal Operation (key switch on, engine on)................................................ 573 BRAKE LOCK CIRCUIT............................................................................. 574 WARNING CIRCUIT................................................................................ 574 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX....................................................... 577 BRAKE CIRCUIT COMPONENT SERVICE.................................................................... 579 BRAKE VALVE.................................................................................... 579 Rebuild Criteria........................................................................... 579 Removal.................................................................................... 579 Installation............................................................................... 581 Disassembly................................................................................ 583 Cleaning and Inspection.................................................................... 585 ASSEMBLY....................................................................................... 585 Actuator Base Threaded Inserts............................................................. 585 Boot and Cap............................................................................... 585 Valve Body Seal Installation............................................................... 586 Regulator Sleeve O-Ring Installation....................................................... 587 Actuator Plunger O-Ring Installation....................................................... 587 Assembly of Valve.......................................................................... 587 DIFFERENTIAL PRESSURE SWITCH................................................................... 588 Disassembly................................................................................ 589 Cleaning and Inspection.................................................................... 589 Assembly................................................................................... 589 VALVE BENCH TEST AND ADJUSTMENT................................................................ 589 Test Set Up Procedure...................................................................... 591 Brake Valve Output Pressure Adjustment..................................................... 591 Differential Pressure Switch Test.......................................................... 592 Final Test and Adjustment.................................................................. 592 Installation Of Brake Pedal Actuator Assembly to Brake Valve............................... 593 HYDRAULIC BRAKE ACCUMULATORS................................................................... 595 Brake Accumulator Bleed-Down Procedure..................................................... 595 Removal.................................................................................... 595 Installation............................................................................... 597 Disassembly................................................................................ 597 Cleaning and Inspection.................................................................... 599 Assembly................................................................................... 599 Leak Testing............................................................................... 602 BRAKE ACCUMULATOR CHARGING..................................................................... 603 Temperature During Precharge............................................................... 605 ACCUMULATOR STORAGE............................................................................ 605 Installation............................................................................... 606 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX..................................................... 607 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................................. 609 EQUIPMENT REQUIRED............................................................................. 612 INITIAL SYSTEM SET-UP.......................................................................... 613 Parking Brake.............................................................................. 613 Service Brakes............................................................................. 614 Brake Lock/Secondary....................................................................... 614 Low Brake Pressure and Auto Apply.......................................................... 615 Reapplications............................................................................. 615 Differential Pressure Switch............................................................... 615 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...................................................... 617 The Brakes are Locked, Service, and/or Parking................................................. 617 Both Brake Circuits are Dragging............................................................... 617 One Brake Circuit is Dragging.................................................................. 617 Brakes are Not Going to Full Pressure.......................................................... 617 A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off......................... 617 Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released.... 618 Differential Pressure Warning Circuit is Not Operating......................................... 618 A Low Brake Pressure Warning Occurs When Brakes are Applied.................................... 618 Low Pressure Warning Circuit Not Operating Properly............................................ 618 Low Pressure Warning is On Even Though System Pressure is Correct.............................. 619 Low Pressure Warning Comes On and Pressure is Low.............................................. 619 A Squeal is Heard When Controller is Operated.................................................. 619 Output Pressure At Controller is Correct but Brakes are Not Applying........................... 619 Brake Pressures Drift Excessively While Pedal is Held Steady................................... 619 Oil is Leaking Around the Pedal Base........................................................... 619 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM....................... 619 CHECK-OUT PROCEDURE................................................................................ 620 HYDRAULIC BRAKE SYSTEM DATA SHEET.................................................................. 620 SECTION J5 FRONT DISC BRAKES INDEX..................................................................... 623 FRONT DISC BRAKES.................................................................................. 625 BRAKE CALIPER.................................................................................. 625 Removal.................................................................................... 625 Installation............................................................................... 626 Disassembly................................................................................ 627 Cleaning and Inspection.................................................................... 627 Assembly................................................................................... 629 BRAKE LINING................................................................................... 629 Replacement................................................................................ 629 FRONT SERVICE BRAKE BURNISHING..................................................................... 631 BRAKE BLEEDING PROCEDURE....................................................................... 632 REAR DISC BRAKES................................................................................... 0 REAR BRAKES.................................................................................... 0 CALIPER, DISC, AND PARKING BRAKE............................................................... 0 Removal.................................................................................... 0 Installation............................................................................... 0 CALIPER PISTON................................................................................. 0 Piston Assembly Removal.................................................................... 0 Inspection................................................................................. 0 Piston Assembly Installation............................................................... 0 FUNCTIONAL TEST OF PISTON ASSEMBLY............................................................. 0 Return Spring Force........................................................................ 0 Built-In Clearance......................................................................... 0 Grip Force................................................................................. 0 Grip Force Measurement..................................................................... 0 Spring Force Measurement................................................................... 0 Disassembly of Piston Assembly............................................................. 0 Assembly of Piston Assembly................................................................ 0 BENCH TEST..................................................................................... 0 BRAKE LINING................................................................................... 0 Replacement................................................................................ 0 SERVICE BRAKE BURNISHING........................................................................... 0 SAFETY PRECAUTIONS............................................................................. 0 Rear Brake Burnishing...................................................................... 0 BRAKE BLEEDING PROCEDURE....................................................................... 0 Spring Force Measurement................................................................... 0 SECTION J6 REAR BRAKES INDEX........................................................................... 633 REAR DISC BRAKES................................................................................... 635 REAR BRAKES.................................................................................... 635 CALIPER, DISC, AND PARKING BRAKE............................................................... 635 Removal.................................................................................... 635 Installation............................................................................... 636 CALIPER PISTON................................................................................. 638 Piston Assembly Removal.................................................................... 638 Inspection................................................................................. 638 Piston Assembly Installation............................................................... 639 FUNCTIONAL TEST OF PISTON ASSEMBLY............................................................. 640 Return Spring Force........................................................................ 640 Built-In Clearance......................................................................... 640 Grip Force................................................................................. 642 Grip Force Measurement..................................................................... 643 Spring Force Measurement................................................................... 645 Disassembly of Piston Assembly............................................................. 646 Assembly of Piston Assembly................................................................ 647 BENCH TEST..................................................................................... 647 BRAKE LINING................................................................................... 648 Replacement................................................................................ 648 SERVICE BRAKE BURNISHING........................................................................... 651 SAFETY PRECAUTIONS............................................................................. 651 Rear Brake Burnishing...................................................................... 652 BRAKE BLEEDING PROCEDURE....................................................................... 653 Spring Force Measurement................................................................... 654 SECTION J7 PARKING BRAKE INDEX......................................................................... 655 PARKING BRAKE...................................................................................... 657 GENERAL INFORMATION............................................................................ 657 PARKING BRAKE CALIPER.......................................................................... 657 Lining Thickness Inspection................................................................ 657 Removal.................................................................................... 658 Installation............................................................................... 658 Parking Brake Adjustment................................................................... 659 Parking Brake Caliper Disassembly.......................................................... 660 Cleaning and Inspection.................................................................... 661 Parking Brake Caliper Assembly............................................................. 662 PARKING BRAKE LINING REPLACEMENT............................................................... 662 PARKING BRAKE BURNISH PROCEDURE................................................................ 662 Lining Conditioning........................................................................ 662 BRAKE BLEEDING PROCEDURE....................................................................... 663 SECTION L HYDRAULIC SYSTEM INDEX........................................................................... 665 SECTION L2 HYDRAULIC SYSTEM INDEX...................................................................... 667 HYDRAULIC SYSTEM................................................................................... 669 GENERAL INFORMATION............................................................................ 669 HYDRAULIC SYSTEMS OPERATION.................................................................... 669 Hoist Circuit Operation.................................................................... 669 Steering Circuit Operation................................................................. 671 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX..................................................... 675 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................................. 677 HOIST PUMP..................................................................................... 677 Removal.................................................................................... 677 Installation............................................................................... 678 Disassembly................................................................................ 679 Inspection of Parts........................................................................ 682 Assembly................................................................................... 682 Troubleshooting Guide...................................................................... 686 HYDRAULIC TANK................................................................................. 687 Filling Instructions....................................................................... 687 Removal.................................................................................... 688 Installation............................................................................... 688 HYDRAULIC TANK STRAINER AND DIFFUSER........................................................... 689 Removal.................................................................................... 689 Inspect and Clean.......................................................................... 690 Installation............................................................................... 690 SECTION L4 STEERING CIRCUIT INDEX...................................................................... 691 STEERING CIRCUIT................................................................................... 693 STEERING CIRCUIT OPERATION..................................................................... 693 COMPONENT DESCRIPTION.......................................................................... 694 Steering Control Valve..................................................................... 694 Unloader Valve............................................................................. 695 Bleed-Down Manifold Valve.................................................................. 695 Flow Amplifier............................................................................. 700 FLOW AMPLIFIER SYSTEM OPERATION................................................................ 701 No Steer................................................................................... 701 Steering Left.............................................................................. 703 Steering Right............................................................................. 705 No Steer, External Shock Load.............................................................. 707 Steering Pump.............................................................................. 709 High Pressure Filter....................................................................... 709 Accumulators............................................................................... 709 Low Precharge Warning Switch............................................................... 709 SECTION L5 STEERING CONTROL VALVE INDEX................................................................ 711 STEERING CONTROL VALVE............................................................................. 713 Removal........................................................................................ 713 Installation................................................................................... 714 STEERING CONTROL VALVE REBUILD................................................................. 715 Disassembly................................................................................ 715 Cleaning and Inspection.................................................................... 716 Assembly................................................................................... 716 BRAKE / STEERING PUMP.......................................................................... 720 Removal.................................................................................... 720 Installation............................................................................... 722 Disassembly................................................................................ 723 Inspection of Parts........................................................................ 723 Assembly................................................................................... 725 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX..................................................... 727 STEERING CIRCUIT COMPONENT REPAIR.................................................................. 729 BLEED-DOWN MANIFOLD............................................................................ 729 Removal.................................................................................... 729 Installation............................................................................... 729 ACCUMULATOR.................................................................................... 730 Removal.................................................................................... 730 Installation............................................................................... 731 Disassembly................................................................................ 732 Cleaning and Inspection.................................................................... 732 Assembly................................................................................... 733 Leak Testing............................................................................... 734 STEERING ACCUMULATOR CHARGING.................................................................. 735 Temperature During Precharge............................................................... 738 ACCUMULATOR STORAGE............................................................................ 739 Installation............................................................................... 739 FLOW AMPLIFIER................................................................................. 740 Removal.................................................................................... 740 Installation............................................................................... 740 Disassembly................................................................................ 741 Assembly................................................................................... 744 STEERING CYLINDERS............................................................................. 745 Disassembly................................................................................ 745 Piston Seal and Bearing Installation....................................................... 745 Cylinder Assembly.......................................................................... 745 Test....................................................................................... 745 TROUBLESHOOTING CHART.............................................................................. 748 SECTION L7 HOIST CIRCUIT INDEX......................................................................... 753 HOIST CIRCUIT...................................................................................... 755 HOIST CIRCUIT OPERATION........................................................................ 755 COMPONENT DESCRIPTION.......................................................................... 756 Hydraulic Tank............................................................................. 756 Hydraulic Pump............................................................................. 756 High Pressure Filter....................................................................... 756 Hoist Valve................................................................................ 756 Hoist Pilot Valve.......................................................................... 757 Bleed-Down Manifold........................................................................ 758 Counterbalance Manifold.................................................................... 758 Hoist-Up Limit Solenoid.................................................................... 758 Pilot Operated Check Valve................................................................. 758 HOIST VALVE OPERATION.......................................................................... 760 Float Operation............................................................................ 760 Power Up Operation (Figure 7-6)............................................................ 762 Hold Operation (Figure 7-7)................................................................ 764 Power Down Operation (Figure 7-8).......................................................... 766 Float Operation (Figure 7-9)............................................................... 768 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX........................................................ 771 HOIST CIRCUIT COMPONENT REPAIR..................................................................... 773 HOIST VALVE.................................................................................... 773 Removal.................................................................................... 773 Installation............................................................................... 773 O-Ring Replacement......................................................................... 775 INLET SECTION.................................................................................. 776 Disassembly................................................................................ 776 Cleaning and Inspection.................................................................... 777 Assembly................................................................................... 777 REAR SPOOL SECTION (WORK PORTS)................................................................ 778 Disassembly................................................................................ 778 Cleaning and Inspection.................................................................... 780 Assembly................................................................................... 780 HOIST PILOT VALVE.............................................................................. 782 Removal.................................................................................... 782 Installation............................................................................... 782 Disassembly................................................................................ 783 Cleaning and Inspection.................................................................... 784 Assembly................................................................................... 784 HOIST UP LIMIT SOLENOID VALVE.................................................................. 785 HOIST CYLINDERS................................................................................ 786 Removal.................................................................................... 786 Installation............................................................................... 787 Disassembly................................................................................ 789 Cleaning and Inspection.................................................................... 790 SS1143 Tightening Tool - Assembly Drawing.................................................. 791 ASSEMBLY OF QUILL AND CYLINDER................................................................. 791 Quill Installation......................................................................... 791 Installation Of Check Balls And Plugs In Quill............................................. 792 Assembly of Cylinder....................................................................... 794 Pressure Testing........................................................................... 795 COUNTERBALANCE MANIFOLD........................................................................ 795 SECTION L9 HIGH PRESSURE FILTERS INDEX................................................................. 797 HYDRAULIC SYSTEM FILTERS........................................................................... 799 HOIST CIRCUIT FILTER........................................................................... 799 Filter Element Replacement................................................................. 799 Removal.................................................................................... 800 Installation............................................................................... 800 Indicator Switch........................................................................... 800 STEERING CIRCUIT FILTER........................................................................ 801 Filter Element Replacement................................................................. 801 Removal.................................................................................... 802 Installation............................................................................... 802 Indicator Switch........................................................................... 802 INDICATOR SWITCH............................................................................... 802 Test Procedure............................................................................. 802 SECTION L10 HYDRAULIC CHECK-OUT PROCEDURE INDEX........................................................ 805 HYDRAULIC CHECK-OUT PROCEDURE...................................................................... 807 INITIAL START UP AND FLUSHING.................................................................. 807 COMPONENT CHECKOUT AND ADJUSTMENT.............................................................. 809 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE.................................. 811 Counterbalance Valve Adjustment............................................................ 813 Manifold Assembly.......................................................................... 813 OIL CLEANLINESS CHECK.......................................................................... 813 Oil Sampling Location On Truck............................................................. 813 Oil Sampling Process and Cleanliness Criteria.............................................. 814 DISABLED TRUCK DUMPING PROCEDURE............................................................... 814 Hookup..................................................................................... 814 Raising the Body........................................................................... 814 Lowering the Body.......................................................................... 815 TROUBLESHOOTING CHART.......................................................................... 816 Hoist Pump................................................................................. 816 Steering Circuit........................................................................... 818 Brake/Steering Pump........................................................................ 820 Flow Amplifier - Refer to Figure 10-9...................................................... 822 SECTION M OPTIONS AND SPECIAL TOOLS INDEX.................................................................. 823 SECTION M7 HEATER OPTIONS INDEX........................................................................ 825 ENGINE OIL HEATERS................................................................................. 827 GENERAL INFORMATION............................................................................ 827 TROUBLESHOOTING................................................................................ 827 HEATER ELEMENT................................................................................. 827 Removal.................................................................................... 827 Installation............................................................................... 828 ENGINE COOLANT HEATER.............................................................................. 829 GENERAL........................................................................................ 829 Maintenance................................................................................ 829 HEATING ELEMENT................................................................................ 829 Removal.................................................................................... 829 Installation............................................................................... 830 THERMOSTAT..................................................................................... 830 Removal.................................................................................... 830 Installation............................................................................... 830 HYDRAULIC OIL HEATERS.............................................................................. 831 GENERAL INFORMATION............................................................................ 831 TROUBLESHOOTING................................................................................ 831 HEATER ELEMENT................................................................................. 831 Removal.................................................................................... 831 Installation............................................................................... 832 SECTION M8 SPECIAL TOOLS INDEX......................................................................... 833 SPECIAL TOOLS...................................................................................... 834 SEAL INSTALLATION RING......................................................................... 838 HYDRAULIC SYSTEM VACUUM PUMP................................................................... 839 RADIATOR SHUTTERS.................................................................................. 0 OPERATION...................................................................................... 0 Hydraulic Circuit.......................................................................... 0 Electrical Circuit:........................................................................ 0 MAINTENANCE AND REPAIR......................................................................... 0 TROUBLESHOOTING................................................................................ 0 Hydraulic Troubleshooting.................................................................. 0 Electrical Troubleshooting................................................................. 0 SECTION M19 RADIATOR SHUTTERS INDEX.................................................................... 843 RADIATOR SHUTTERS.................................................................................. 845 OPERATION...................................................................................... 845 Hydraulic Circuit.......................................................................... 845 Electrical Circuit:........................................................................ 846 MAINTENANCE AND REPAIR......................................................................... 846 TROUBLESHOOTING................................................................................ 847 Hydraulic Troubleshooting.................................................................. 850 Electrical Troubleshooting................................................................. 852 SECTION N OPERATOR'S CAB INDEX............................................................................. 853 SECTION N2 TRUCK CAB INDEX............................................................................. 855 TRUCK CAB.......................................................................................... 857 TRUCK CAB...................................................................................... 857 Description................................................................................ 857 Removal.................................................................................... 858 Installation............................................................................... 860 CAB DOOR....................................................................................... 860 Removal.................................................................................... 860 Installation............................................................................... 861 Door Adjustment............................................................................ 861 Door Jam Bolt Adjustment................................................................... 861 Door Handle Plunger Adjustment............................................................. 863 Replace Door Glass......................................................................... 864 Replace Door Window Regulator.............................................................. 868 Replace Door Handle or Latch Assembly...................................................... 868 Door and Door Hinge Seal Replacement....................................................... 869 Door Opening Seal Removal.................................................................. 869 Installation............................................................................... 869 GLASS REPLACEMENT.............................................................................. 870 Adhesive-Bonded Windows.................................................................... 870 Recommended Tools/Supplies................................................................. 870 Replacement Procedure...................................................................... 870 Windshield and Rear Glass.................................................................. 871 Removal.................................................................................... 871 Installation............................................................................... 872 REMOVAL AND INSTALLATION OF OPERATOR SEAT...................................................... 873 Inspection................................................................................. 873 Removal.................................................................................... 873 Installation............................................................................... 873 REMOVAL AND INSTALLATION OF PASSENGER SEAT..................................................... 874 Removal.................................................................................... 874 Installation............................................................................... 874 SECTION N3 CAB COMPONENTS INDEX........................................................................ 875 CAB COMPONENTS..................................................................................... 877 WINDSHIELD WIPERS.................................................................................. 877 WIPER MOTOR REPLACEMENT........................................................................ 877 Removal.................................................................................... 877 Installation............................................................................... 877 WIPER ARM REPLACEMENT.......................................................................... 877 Removal.................................................................................... 877 Installation............................................................................... 878 WIPER LINKAGE REPLACEMENT...................................................................... 878 Removal.................................................................................... 878 Installation............................................................................... 879 WINDSHIELD WASHER.............................................................................. 879 Operation.................................................................................. 879 Service.................................................................................... 879 SECTION N4 OPERATOR COMFORT INDEX...................................................................... 881 OPERATOR COMFORT................................................................................... 883 HEATER / AIR CONDITIONER....................................................................... 883 Fan Speed Control Knob..................................................................... 883 Temperature Control Knob................................................................... 883 Air Flow Directional Knob.................................................................. 883 Heater/Air Conditioner Vents............................................................... 884 COMPONENTS..................................................................................... 884 Fuse and Circuit Breaker................................................................... 884 Relays..................................................................................... 884 Heater Core................................................................................ 884 Fan Motor And Speed Control................................................................ 885 Actuators.................................................................................. 885 Cab Air Filter............................................................................. 885 ENVIRONMENTAL IMPACT OF AIR CONDITIONING....................................................... 888 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES...................................................... 888 PRINCIPLES OF REFRIGERATION.................................................................... 888 Air Conditioning........................................................................... 888 Refrigeration - The Act Of Cooling......................................................... 889 The Refrigeration Cycle.................................................................... 889 AIR CONDITIONER SYSTEM COMPONENTS.............................................................. 890 Compressor (Refrigerant Pump).............................................................. 890 Service Valves............................................................................. 890 Condenser.................................................................................. 890 Receiver-Drier............................................................................. 890 Expansion Block Valve...................................................................... 891 Accumulator................................................................................ 891 Evaporator................................................................................. 891 ELECTRICAL CIRCUIT............................................................................. 892 Thermostat................................................................................. 892 Compressor Clutch.......................................................................... 892 Trinary™ Switch............................................................................ 893 SYSTEM SERVICING............................................................................... 894 SERVICE TOOLS AND EQUIPMENT.................................................................... 895 Recovery/Recycle Station................................................................... 895 Leak Detector.............................................................................. 895 Service Valves............................................................................. 896 Vacuum Pump................................................................................ 896 Manifold Gauge Set......................................................................... 897 Installing Manifold Gauge Set.............................................................. 898 Purging Air From Service Hoses............................................................. 898 SYSTEM PERFORMANCE TEST........................................................................ 899 SYSTEM OIL..................................................................................... 900 Handling and Reusing PAG Oil............................................................... 900 Oil Quantity............................................................................... 900 Checking System Oil........................................................................ 900 REFRIGERANT.................................................................................... 901 Recycled Refrigerant....................................................................... 901 Reclaimed Refrigerant...................................................................... 901 Refrigerant Quantity....................................................................... 901 R-134a Refrigerant Containers.............................................................. 902 SYSTEM LEAK TESTING............................................................................ 902 Electronic Leak Detector................................................................... 903 Tracer Dyes................................................................................ 903 Soap and Water............................................................................. 903 RECOVERING AND RECYCLING THE REFRIGERANT....................................................... 903 Draining Oil from the Previous Recovery Cycle.............................................. 903 Performing the Recovery Cycle.............................................................. 903 Performing the Recycling Procedure......................................................... 904 Evacuating and Charging the A/C System..................................................... 904 SYSTEM REPAIR.................................................................................. 904 System Flushing............................................................................ 904 A/C DRIVE BELT CHECKOUT PROCEDURE.............................................................. 905 Pulley Alignment........................................................................... 905 Belt Tension Check......................................................................... 905 COMPONENT REPLACEMENT.......................................................................... 907 Hoses and Fittings......................................................................... 907 Lines...................................................................................... 907 Expansion Valve............................................................................ 907 Receiver-Drier............................................................................. 907 Thermostat................................................................................. 907 Compressor................................................................................. 908 Accumulator................................................................................ 908 Clutch..................................................................................... 908 Servicing the Compressor Clutch............................................................ 909 Pulley Removal............................................................................. 911 Clutch Coil Check.......................................................................... 912 Pulley Installation........................................................................ 912 Clutch Assembly Installation............................................................... 912 EVACUATING THE SYSTEM.......................................................................... 914 CHARGING THE A/C SYSTEM........................................................................ 916 TROUBLESHOOTING.................................................................................... 917 Preliminary Checks............................................................................. 917 Diagnosis Of Gauge Readings And System Performance............................................. 917 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS..................................................... 918 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................................... 924 SECTION N5 OPERATOR CONTROLS AND EQUIPMENT INDEX....................................................... 925 OPERATOR CAB AND CONTROLS.......................................................................... 927 STEERING WHEEL AND CONTROLS........................................................................ 928 HORN BUTTON.................................................................................... 928 TILT/TELESCOPE LEVER........................................................................... 928 M ULTI-FUNCTION TURN SIGNAL SWITCH............................................................. 928 Turn Signal Operation...................................................................... 928 High Beam Headlight Operation.............................................................. 928 Windshield Wiper Operation................................................................. 928 STEERING COLUMN................................................................................ 929 Removal.................................................................................... 929 Inspection................................................................................. 929 Installation............................................................................... 930 STEERING WHEEL................................................................................. 930 Removal.................................................................................... 930 Installation............................................................................... 930 PEDALS............................................................................................. 932 SERVICE BRAKE PEDAL............................................................................ 932 DYNAMIC RETARDER PEDAL......................................................................... 932 Optional - Dual Function/Single Pedal...................................................... 932 THROTTLE PEDAL................................................................................. 932 GRADE/SPEED WARNING CHART...................................................................... 933 OVERHEAD PANEL CONTROLS AND COMPONENTS............................................................. 933 RADIO SPEAKERS................................................................................. 933 WARNING ALARM BUZZER........................................................................... 933 CAB RADIO...................................................................................... 933 WARNING LIGHTS DIMMER CONTROL.................................................................. 933 WARNING/STATUS INDICATOR LIGHT PANEL........................................................... 933 AIR CLEANER VACUUM GAUGES...................................................................... 933 WINDSHIELD WIPERS.............................................................................. 933 TRUCK CONTROLS................................................................................. 934 F-N-R Selector Switch...................................................................... 934 Hoist Control Lever........................................................................ 935 CONSOLE SWITCHES AND CONTROLS.................................................................. 935 Ashtray.................................................................................... 935 Cigarette Lighter.......................................................................... 935 Left-Hand Window Control Switch............................................................ 935 Right-Hand Window Control Switch........................................................... 935 Engine Shutdown Switch..................................................................... 935 Override Switch............................................................................ 935 Retard Speed Control (RSC) Switch.......................................................... 936 Retard Speed Control (RSC) Dial............................................................ 936 Statex III Download Port................................................................... 937 Engine Diagnostic Port (CENSE)............................................................. 937 Modular Mining Port........................................................................ 937 Passenger Seat............................................................................. 937 Engine Diagnostic Connectors............................................................... 937 Engine Diagnostics Connector............................................................... 937 Data Store Button.......................................................................... 937 PAYLOAD METER.................................................................................. 937 Payload Meter Download Connector........................................................... 937 OPERATOR’S SEAT.................................................................................... 938 Seat Belts..................................................................................... 938 Adjustment..................................................................................... 938 INSTRUMENT PANEL................................................................................... 939 CONTROL SYMBOLS................................................................................ 939 CONTROL SWITCHES AND GAUGES.................................................................... 940 Key Switch................................................................................. 940 Engine Shutdown Switch With Timer Delay.................................................... 941 Fog Light Switch........................................................................... 941 Ladder Light Switch........................................................................ 941 Backup Light Switch........................................................................ 941 Panel Illumination Lights.................................................................. 941 Cab Air Conditioner/Heater Vents........................................................... 941 Engine Cold Weather Starting Aid Switch.................................................... 941 Rotating Beacon Light Switch............................................................... 941 Heated Mirror Switch....................................................................... 941 Wheel Brake Lock Switch.................................................................... 942 Parking Brake Switch....................................................................... 942 Digital Tachometer......................................................................... 942 Right Turn Signal Indicator Light.......................................................... 943 High Beam Headlight Indicator Light........................................................ 943 Left Turn Signal Indicator Light........................................................... 943 Digital Speedometer/Payload Meter Display.................................................. 943 Voltmeter Gauge............................................................................ 943 Engine Oil Pressure Gauge.................................................................. 943 Engine Water Temperature Gauge............................................................. 943 Fuel Gauge................................................................................. 943 Engine Hourmeter........................................................................... 943 Headlight Switch........................................................................... 944 Panel Illumination Lights Dimmer Rheostat.................................................. 944 Payload Meter Switch....................................................................... 944 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL...................................................... 945 DESCRIPTION OF INDICATOR SYMBOLS............................................................... 945 INDICATOR LIGHT FUNCTIONS...................................................................... 946 A1. High Hydraulic Oil Temperature......................................................... 946 B1. Low Steering Pressure.................................................................. 946 C1. Low Accumulator Precharge Pressure..................................................... 947 D1. Electric System Fault.................................................................. 947 E1. Low Brake Pressure..................................................................... 947 A2. Low Hydraulic Tank Level............................................................... 947 B2. Automatic Lubrication System Pressure.................................................. 947 C2. Circuit Breaker Tripped................................................................ 947 D2. Hydraulic Oil Filter Monitor........................................................... 948 E2. Low Fuel............................................................................... 948 A3. Parking Brake.......................................................................... 948 B3. Service Brake.......................................................................... 948 C3. Body Up................................................................................ 948 D3. Dynamic Retarding...................................................................... 948 E3. Stop Engine............................................................................ 948 A4. Not Used............................................................................... 949 B4. Manual Backup Lights................................................................... 949 C4. Engine Shutdown Timer.................................................................. 949 D4. Retard Speed Control (RSC)............................................................. 949 E4. Check Engine........................................................................... 949 A5. Service Engine Indicator (AEM)......................................................... 949 B5. High Wheel Motor Temperature........................................................... 949 C5. Blower Fault........................................................................... 949 D5, E5, A6, B6, and C6. Not Used........................................................... 949 D6. Service Engine (CENSE)................................................................. 949 E6. Not Used............................................................................... 949 Komatsu Engines w/Centry™ Fuel Control..................................................... 950 Hazard Warning Light Switch................................................................ 950 Lamp Test Switch/Centry™ Diagnostic Test Switch............................................ 950 REAR AXLE LIGHT BAR................................................................................ 951 Backup Lights.................................................................................. 951 Retard Lights.................................................................................. 951 Brake Light.................................................................................... 951 Backup Alarm................................................................................... 951 KOMTRAX Plus................................................................................... 952 Operation.................................................................................. 952 Interface Module........................................................................... 954 Basic Precautions.......................................................................... 954 CENTRY™ FUEL SYSTEM DIAGNOSTICS.................................................................... 955 GENERAL OPERATION.............................................................................. 955 DETERMINING FAULT CODES........................................................................ 955 EXITING THE DIAGNOSTICS MODE................................................................... 956 SECTION P LUBRICATION AND SERVICE INDEX.................................................................... 957 SECTION P2 LUBRICATION AND SERVICE INDEX............................................................... 959 LUBRICATION AND SERVICE............................................................................ 961 GENERAL INFORMATION............................................................................ 961 HYDRAULIC TANK SERVICE......................................................................... 961 Adding Oil................................................................................. 961 COOLANT LEVEL CHECK............................................................................ 962 Radiator Filling Procedure................................................................. 962 Coolant Specifications..................................................................... 962 Unacceptable Practices..................................................................... 962 WHEEL MOTOR SERVICE............................................................................ 962 RESERVE ENGINE OIL SYSTEM (Optional)........................................................... 963 Reserve Oil Tank Filling Procedure (Remote fill)........................................... 963 Inline Screen.............................................................................. 963 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS........................................................ 965 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)............................................ 966 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................................... 967 100 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 967 250 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 968 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)............................................ 969 500 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 970 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)............................................ 971 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 972 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 973 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 973 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 974 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................................... 975 SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX.......................................................... 977 AUTOMATIC LUBRICATION SYSTEM....................................................................... 979 GENERAL DESCRIPTION............................................................................ 979 SYSTEM COMPONENTS.............................................................................. 980 Filter Assembly............................................................................ 980 Hydraulic Motor and Grease Pump............................................................ 980 Reservoir.................................................................................. 980 Fixed Pressure Reducing Valve.............................................................. 980 Flow Control Valve......................................................................... 980 Solenoid Valve............................................................................. 981 Vent Valve................................................................................. 981 24VDC Lubrication Cycle Timer.............................................................. 981 Time Delay Module.......................................................................... 981 Pump Cutoff Pressure Switch................................................................ 981 Unloader Valve............................................................................. 981 Pressure Switch............................................................................ 981 Manual Override Button..................................................................... 981 Injectors.................................................................................. 981 SYSTEM OPERATION............................................................................... 984 Normal Operation........................................................................... 984 Pressure Failure Detection Circuits........................................................ 985 GENERAL INSTRUCTIONS............................................................................... 986 LUBRICANT REQUIRED FOR SYSTEM.................................................................. 986 SYSTEM PRIMING................................................................................. 986 LUBRICANT PUMP................................................................................. 987 Pump Housing Oil Level..................................................................... 987 Pump Pressure Control...................................................................... 987 FILTER AND RESERVOIR........................................................................... 987 Filter Assembly Element.................................................................... 988 INJECTORS (SL-1 Series H)...................................................................... 988 Injector Specifications.................................................................... 988 Injector Adjustment........................................................................ 988 INJECTOR OPERATION............................................................................. 990 SYSTEM CHECKOUT................................................................................ 991 Lubrication Cycle Timer Check.............................................................. 991 Lubrication Cycle Timer Adjustment......................................................... 992 PREVENTIVE MAINTENANCE INSPECTION.............................................................. 992 10 Hour Lubrication System Inspection...................................................... 992 100 Hour Inspection........................................................................ 992 250 Hour Inspection........................................................................ 992 500 Hour Inspection........................................................................ 993 1000 Hour Inspection....................................................................... 993 PUMP REBUILD................................................................................... 994 Disassembly................................................................................ 994 Cleaning and Inspection.................................................................... 994 Assembly................................................................................... 996 VENT VALVE REBUILD............................................................................. 997 Disassembly and Assembly................................................................... 997 SYSTEM TROUBLESHOOTING CHART................................................................... 998 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 0 AXLE BOX....................................................................................... 0 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 0 ARMATURE AREA.................................................................................. 0 AT TIRE CHANGE................................................................................. 0 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 0 GENERATOR/ALTERNATOR........................................................................... 0 GRID BLOWER MOTOR.............................................................................. 0 CONTROL EQUIPMENT CHECKS....................................................................... 0 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 0 VEHICLE OPERATIONS TESTS....................................................................... 0 SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX..................................................1001 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1003 AXLE BOX.......................................................................................1003 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1004 ARMATURE AREA..................................................................................1004 AT TIRE CHANGE.................................................................................1004 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1005 GENERATOR/ALTERNATOR...........................................................................1005 GRID BLOWER MOTOR..............................................................................1005 CONTROL EQUIPMENT CHECKS.......................................................................1005 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1006 VEHICLE OPERATIONS TESTS.......................................................................1006 SECTION R SYSTEM SCHEMATICS INDEX..........................................................................1007 EK5755 HYDRAULIC BRAKE SCHEMATIC ......................................................................1009 EJ2729 HYDRAULIC SYSTEM SCHEMATIC .....................................................................1010 EL8720 VHMS ELECTRICAL SCHEMATIC ......................................................................1011 HE484 HVAC ELECTRICAL SCHEMATIC .......................................................................1016 XS6500 ELECTRICAL SYSTEMS SCHEMATIC ...................................................................1017
DESCRIPTION:
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30620, A30522 – A30632) KOMATSU 730E
- This manual is written for use by the service technician. It is designed to help these persons to become fully knowl- edgeable 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 gen- eral 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 US. 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 :L-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 manu- facturing 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.
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