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Komatsu 730E Dump Truck Shop Manual A30427-A30538 – PDF DOWNLOAD
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Komatsu 730E Dump Truck Shop Manual
SERIAL NUMBERS A30427 – A30538
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Description
Komatsu 730E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 730E Dump Truck Shop Manual
Language : English
Pages : 1102
Downloadable : Yes
File Type : PDF
Size: 32.6 MB
Book Code: CEBM018000
DESCRIPTION:
Komatsu 730E Dump Truck Shop Manual
FOREWORD:
This manual is written for use by the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information.
- The major portion of the manual pertains to disassembly, service, and reassembly. Each major serviceable component has a section in the shop manual. Disassembly of any component should only be done as far as necessary to accomplish needed repairs.
- The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning in metric units and in U.S. English units. All references to Right, Left, Front, or Rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements for common fasteners are shown in torque charts in the general information section.
- Special torque requirtements are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
- The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter E, when present, designates an electrical wheel motor drive system.
- The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
TABLE OF CONTENTS:
Komatsu 730E Dump Truck Shop Manual
COVER............................................................................................... 1 FOREWORD............................................................................................ 5 TABLE OF CONTENTS................................................................................... 7 SECTION A - GENERAL INFORMATION - INDEX............................................................. 9 SECTION A2 - MAJOR COMPONENT DESCRIPTION........................................................ 11 SECTION A3 - GENERAL SAFETY..................................................................... 15 GENERAL SAFETY AND OPERATION................................................................ 17 PERSONAL SAFETY......................................................................... 17 Safety Rules........................................................................ 17 Truck Safety Features............................................................... 17 Clothing And Personal Items......................................................... 17 Unauthorized Modification........................................................... 17 Leaving The Operator’s Seat......................................................... 17 Mounting And Dismounting............................................................ 18 Fire Extinguishers And First Aid Kits............................................... 18 Precautions For High Temperature Fluids............................................. 18 Asbestos Dust Hazard Prevention..................................................... 19 Fire Prevention For Fuel And Oil.................................................... 19 ROPS Precautions.................................................................... 19 Preventing Injury From Work Equipment............................................... 19 Precautions For Optional Attachments................................................ 19 Precautions When Starting The Machine............................................... 20 PRECAUTIONS FOR TRUCK OPERATION......................................................... 20 Safety Is Thinking Ahead............................................................ 20 Safety At The Work Site............................................................. 20 Fire Prevention..................................................................... 20 Preparing For Operation............................................................. 20 Ventilation For Enclosed Areas...................................................... 20 Mirrors, Windows, And Lights........................................................ 21 In The Operator’s Cab - Before Starting The Engine.................................. 21 OPERATING THE MACHINE................................................................... 21 Starting The Engine................................................................. 21 Truck Operation - General........................................................... 21 Traveling In The Truck.............................................................. 22 Precautions When Traveling In Reverse............................................... 22 Traveling On Slopes................................................................. 22 Ensuring Good Visibility............................................................ 23 Operating On Snow................................................................... 23 Avoid Damage To The Dump Body....................................................... 23 Driving Near High-Voltage Cables.................................................... 23 When Loading The Truck.............................................................. 23 When Dumping........................................................................ 23 Working On Loose Ground............................................................. 24 Parking The Machine................................................................. 24 TOWING.................................................................................. 24 WORKING NEAR BATTERIES.................................................................. 24 Battery Hazard Prevention........................................................... 24 Jump-Starting With Booster Cables................................................... 25 PRECAUTIONS FOR MAINTENANCE................................................................. 26 BEFORE PERFORMING MAINTENANCE........................................................... 26 Stopping The Engine Before Service.................................................. 26 Warning Tag......................................................................... 26 Proper Tools........................................................................ 26 Securing The Dump Body.............................................................. 26 DURING MAINTENANCE...................................................................... 27 Personnel........................................................................... 27 Attachments......................................................................... 27 Working Under The Machine........................................................... 27 Keeping The Machine Clean........................................................... 27 Rules To Follow When Adding Fuel Or Oil............................................. 27 Radiator Coolant Level.............................................................. 27 Use Of Lighting..................................................................... 28 Precautions With The Battery........................................................ 28 Handling High-Pressure Hoses........................................................ 28 Precautions With High-Pressure Oil.................................................. 28 Maintenance Near High Temperatures And High Pressures............................... 28 Rotating Fan And Belts.............................................................. 28 Waste Materials..................................................................... 28 TIRES................................................................................... 29 Handling Tires...................................................................... 29 Tire Maintenance.................................................................... 29 Storing Tires After Removal......................................................... 30 ADDITIONAL JOB SITE RULES................................................................... 31 WHEN REPAIRS ARE NECESSARY.................................................................. 32 OPERATING INSTRUCTIONS...................................................................... 33 PREPARING FOR OPERATION................................................................. 33 SAFETY IS THINKING AHEAD................................................................ 33 WALK-AROUND INSPECTION.................................................................. 33 ENGINE START-UP......................................................................... 37 AFTER ENGINE HAS STARTED................................................................ 38 MACHINE OPERATION SAFETY PRECAUTIONS.................................................... 39 LOADING................................................................................. 39 HAULING................................................................................. 40 PASSING................................................................................. 40 DUMPING................................................................................. 40 To Raise The Dump Body:............................................................. 41 To Lower The Dump Body: (When dumping over a berm or into a crusher):............... 41 To Lower The Dump Body (When dumping on flat ground):............................... 42 TOWING.................................................................................. 42 SAFE PARKING PROCEDURES................................................................. 43 ENGINE SHUTDOWN PROCEDURE............................................................... 43 DELAYED ENGINE SHUTDOWN PROCEDURE....................................................... 43 SUDDEN LOSS OF POWER.................................................................... 44 EMERGENCY STEERING SYSTEM............................................................... 44 Operation........................................................................... 44 Testing............................................................................. 45 SECTION A4 - WARNINGS AND CAUTIONS.............................................................. 47 SECTION A5 -STANDARD TORQUE CHARTS AND CONVERSION TABLES........................................ 55 SECTION A7 - STORAGE AND IDLE MACHINE PREPARATION - INDEX....................................... 61 STORAGE AND IDLE MACHINE PREPARATION........................................................ 63 SHORT TERM IDLE PERIODS................................................................. 63 PREPARATION FOR STORAGE................................................................. 64 REMOVAL FROM STORAGE.................................................................... 65 RECONDITIONING AN IDLE VEHICLE.......................................................... 66 ENGINE OPERATION........................................................................ 69 After The Engine Has Started........................................................ 69 ENGINE STORAGE.......................................................................... 70 Temporary Storage (30 Days Or Less)................................................. 70 Extended Storage (More Than 30 Days)................................................ 71 RESTORING AN ENGINE AFTER EXTENDED STORAGE.............................................. 72 ELECTRIC DRIVE TRUCKS................................................................... 73 Storing A Truck That Is Operational................................................. 73 Storing A Truck That Is Not Operational............................................. 74 Storing A Major Component........................................................... 75 Periodic Inspections................................................................ 75 Placing Equipment Into Service After Storage........................................ 75 SECTION B - STRUCTURES - INDEX...................................................................... 77 SECTION B2 - STRUCTURAL COMPONENTS - INDEX...................................................... 79 STRUCTURAL COMPONENTS....................................................................... 81 LADDERS................................................................................. 81 Removal............................................................................. 81 Installation........................................................................ 81 GRILLE AND HOOD......................................................................... 82 Removal............................................................................. 82 Installation........................................................................ 82 RIGHT-HAND DECK......................................................................... 82 Removal............................................................................. 82 Installation........................................................................ 84 CENTER DECK............................................................................. 84 LEFT-HAND DECK.......................................................................... 85 Removal............................................................................. 85 Installation........................................................................ 85 SECTION B3 - DUMP BODY - INDEX.................................................................. 87 DUMP BODY................................................................................... 89 DUMP BODY............................................................................... 89 Removal............................................................................. 89 Installation........................................................................ 90 BODY SLING.............................................................................. 90 BODY PADS............................................................................... 91 Adjustment.......................................................................... 91 BODY GUIDE.............................................................................. 92 BODY POSITION INDICATOR................................................................. 92 HOIST LIMIT SWITCH...................................................................... 92 ROCK EJECTORS........................................................................... 92 Inspection.......................................................................... 92 SECTION B4 - FUEL TANK - INDEXINDEX............................................................. 93 FUEL TANK................................................................................... 95 Removal................................................................................. 95 Repair.................................................................................. 95 Cleaning................................................................................ 95 Installation............................................................................ 96 FUEL GAUGE SENDER........................................................................... 97 Removal................................................................................. 97 Installation............................................................................ 97 LOW FUEL SENDER............................................................................. 98 Removal................................................................................. 98 Installation............................................................................ 98 FUEL RECEIVER............................................................................... 99 TANK BREATHER VALVE......................................................................... 100 Removal................................................................................. 100 Installation............................................................................ 100 Disassembly............................................................................. 100 Assembly................................................................................ 100 SECTION C - ENGINE - INDEX.......................................................................... 101 SECTION C2 - POWER MODULE - INDEX............................................................... 103 POWER MODULE................................................................................ 105 GENERAL INFORMATION..................................................................... 105 POWER MODULE SERVICE.................................................................... 106 Removal............................................................................. 106 Installation........................................................................ 110 SECTION C3 - COOLING SYSTEM - INDEX............................................................. 113 COOLING SYSTEM.............................................................................. 115 RADIATOR................................................................................ 115 Removal............................................................................. 115 Service............................................................................. 116 Installation........................................................................ 116 RADIATOR FILL PROCEDURE............................................................. 117 RADIATOR REPAIR..................................................................... 117 Internal Inspection............................................................. 117 External Cleaning............................................................... 118 Disassembly..................................................................... 118 Cleaning and Inspection......................................................... 119 Assembly........................................................................ 119 Additional Service Information.................................................. 121 PRESSURE TESTING.................................................................... 121 COOLANT SYSTEM TROUBLESHOOTING...................................................... 121 SECTION C4 - POWER TRAIN - INDEX................................................................ 123 POWER TRAIN................................................................................. 125 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE........................................... 125 General Information................................................................. 125 Removal............................................................................. 125 ALTERNATOR INSTALLATION................................................................. 127 Engine/Alternator Mating............................................................ 127 Alternator Measurement.............................................................. 127 Engine End Play Measurement......................................................... 128 Determining Shim Requirements....................................................... 129 Installing Alternator On Engine..................................................... 130 ENGINE.................................................................................. 131 Removal............................................................................. 131 Installation........................................................................ 131 SECTION C5 - AIR CLEANERS - INDEX............................................................... 133 AIR CLEANERS................................................................................ 135 Service Checks.......................................................................... 135 Filter Element Replacement.............................................................. 136 Main Filter Element Cleaning............................................................ 138 Precleaner Section...................................................................... 139 Cleaning Precleaner Tubes............................................................... 139 Air Intake Troubleshooting.............................................................. 140 SECTION C7 - FAN DRIVE CLUTCH - INDEX........................................................... 141 FAN DRIVE CLUTCH............................................................................ 143 GENERAL DESCRIPTION..................................................................... 143 COMPONENTS.............................................................................. 143 Input............................................................................... 143 Output.............................................................................. 143 Stationary Components............................................................... 144 OPERATION MODES......................................................................... 145 Fully Engaged....................................................................... 145 Modulated Variable Speed............................................................ 145 Fully Released...................................................................... 146 Remember:........................................................................... 146 Lubricating and Cooling Oil......................................................... 147 MAINTENANCE............................................................................. 148 Maintenance Checks To Be Made....................................................... 148 TROUBLESHOOTING......................................................................... 149 Basic Preliminary Checks............................................................ 149 FIELD CHECK DIAGNOSIS................................................................... 150 Preliminary Checks With Engine Off.................................................. 150 Check Clutch Release................................................................ 150 Check Clutch Lock-up................................................................ 151 Overheating Complaint............................................................... 152 Thermal Sensor and Solenoid Valve................................................... 152 On Truck Test....................................................................... 152 Off Truck Test...................................................................... 153 Test Conditions and Requirements:................................................... 153 Test:............................................................................... 153 TROUBLESHOOTING CHART....................................................................... 154 FAN CLUTCH DISASSEMBLY INSTRUCTIONS......................................................... 157 REASSEMBLY OF THE FAN CLUTCH................................................................ 164 INSPECTION OF PARTS......................................................................... 175 REBUILD TOOLS............................................................................... 178 SECTION D - ELECTRICAL SYSTEM - INDEX............................................................... 181 SECTION D2 - 24 VDC ELECTRICAL SUPPLY SYSTEM - INDEX............................................ 183 24VDC ELECTRIC SUPPLY SYSTEM................................................................ 185 ELECTRICAL SYSTEM DESCRIPTION........................................................... 185 BATTERIES............................................................................... 185 Maintenance and Service............................................................. 185 Troubleshooting..................................................................... 185 BATTERY CHARGING ALTERNATOR............................................................. 187 24VDC ELECTRIC START SYSTEM............................................................. 187 CRANKING MOTORS..................................................................... 187 Removal......................................................................... 187 Installation.................................................................... 188 CRANKING MOTOR TROUBLESHOOTING...................................................... 188 Preliminary Inspection.......................................................... 189 No-Load Test.................................................................... 189 Interpreting Results of Tests................................................... 189 Disassembly..................................................................... 190 Cleaning and Inspection......................................................... 190 Armature Servicing.............................................................. 190 Field Coil Checks............................................................... 193 Field Coil Removal.............................................................. 193 Solenoid Checks................................................................. 193 Test............................................................................ 193 Assembly........................................................................ 194 Pinion Clearance................................................................ 195 MAGNETIC SWITCH..................................................................... 196 Coil Test....................................................................... 196 Electric Start System Wiring Diagrams........................................... 196 ENGINE PRELUB SYSTEM.................................................................... 196 OPERATION........................................................................... 196 Pressure Switch................................................................. 197 Suction Line.................................................................... 197 Outlet Line..................................................................... 197 Check Valve..................................................................... 197 Solenoid Timer.................................................................. 197 TROUBLESHOOTING PRELUB STARTER CIRCUIT.................................................. 199 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX......................................... 203 24VDC ELECTRICAL SYSTEM COMPONENTS.......................................................... 205 PASSENGER SEAT BASE COMPARTMENT......................................................... 205 COMPONENTS.............................................................................. 205 Taillight Resistor Diode Assemblies................................................. 205 Inclinometer........................................................................ 205 Brake Warning Buzzer (BWB).......................................................... 205 Lubrication System Timer............................................................ 205 Five Minute Idle Timer Components................................................... 205 Five Minute Idle Timer.............................................................. 207 Five Minute Idle Relay.............................................................. 207 Five Minute Idle Contactor.......................................................... 207 Five Minute Idle Circuit Test....................................................... 207 Data Store Switch................................................................... 207 Komatsu Engine Quantum Connector (Not Used)......................................... 207 Komatsu Engine Cense Connector...................................................... 207 STATEX III Propulsion System Diagnostic Connector................................... 207 Spare Connector Location............................................................ 207 Alarm Indicating Device (AID) System................................................ 208 Diode Matrix (Without Sound)........................................................ 208 Diode Matrix (With Sound)........................................................... 209 Hot Switch Inverter................................................................. 209 Hot Switch Inverter Card (Slot 4) (Not Used)........................................ 209 Temperature......................................................................... 209 Oil Level........................................................................... 209 Temperature and Latch............................................................... 209 Coolant Level/Flasher............................................................... 210 Lamp Test........................................................................... 210 BATTERY EQUALIZER BOX................................................................... 210 Troubleshooting..................................................................... 210 BODY-UP SWITCH.......................................................................... 211 Adjustment.......................................................................... 211 Service............................................................................. 211 HOIST LIMIT SWITCH...................................................................... 212 Adjustment.......................................................................... 212 Service............................................................................. 212 24-VOLT RELAY AND DIODE BOARDS.......................................................... 212 RELAY BOARDS............................................................................ 213 Description......................................................................... 213 SERVICE................................................................................. 213 To Replace A Relay:................................................................. 213 To Replace A Circuit Breaker:....................................................... 213 To Replace A Circuit Panel Card..................................................... 214 Relay Board Components.............................................................. 214 Installing Additional Circuits...................................................... 215 DIODE BOARD 1....................................................................... 216 Diode Testing....................................................................... 216 CIRCUIT BREAKERS........................................................................ 218 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX............................................... 219 BATTERY CHARGING SYSTEM..................................................................... 223 BATTERY CHARGING SYSTEM................................................................. 223 ELECTRICAL SYSTEM DESCRIPTION....................................................... 223 CHARGE VOLT AND AMP VALUES.......................................................... 223 BATTERY............................................................................. 223 Maintenance and Service......................................................... 223 Troubleshooting................................................................. 224 Undercharging................................................................... 224 Overcharging.................................................................... 224 Corrosion....................................................................... 224 Acid Levels..................................................................... 224 Non-Use or Storage.............................................................. 224 Freezing........................................................................ 225 BATTERY CHARGING ALTERNATOR............................................................. 226 GENERAL INFORMATION................................................................. 226 General Description............................................................. 226 Terminal Identification and Location............................................ 227 Battery Positive (B+)........................................................... 227 Battery Negative (B-)........................................................... 227 DC Output (D+).................................................................. 227 AC Output (R)................................................................... 227 Regulator Harness Plug Identification........................................... 227 Alternator Specifications....................................................... 227 Performance Curve............................................................... 227 Battery/Alternator Terminology.................................................. 228 WIRING DIAGRAM...................................................................... 230 DIMENSIONS AND TORQUE VALUES........................................................ 231 PERIODIC MAINTENANCE................................................................ 232 TESTING................................................................................. 232 GENERAL INFORMATION................................................................. 232 Troubleshooting Alternator (On-Truck)........................................... 232 Equipment Required.............................................................. 232 Preliminary Checks.............................................................. 232 Test Set-up..................................................................... 234 Test Procedure.................................................................. 235 REGULATOR TESTING................................................................... 236 Regulator Bypass Test (No Output)............................................... 236 Regulator Bypass Test (Amp Rating).............................................. 237 BENCH TESTING....................................................................... 238 Equipment....................................................................... 238 Identification Record........................................................... 238 Advanced Troubleshooting........................................................ 238 Bench Test 1: No-Load Test...................................................... 238 Bench Test 2: Full Load Test.................................................... 239 Bench Test 3: Regulator Bypass Test............................................. 239 STATIC TESTING...................................................................... 240 Equipment....................................................................... 240 Identification Record........................................................... 240 Regulator Tester................................................................ 240 Check For Shorted Power Transistor.............................................. 240 Circuit Tests................................................................... 241 FIELD COIL TESTS.................................................................... 242 Field Coil Test 1: Check for Open or Shorted Field Coil......................... 242 Field Coil Test 2: Check For Grounded Field Coil................................ 242 STATOR TESTS........................................................................ 243 Stator Test 1: Check For Stator-To-Stator Continuity............................ 243 Stator Test 2: Check For Grounded Stators....................................... 244 THERMAL SWITCH TEST................................................................. 244 Initial Test.................................................................... 244 Verifying a Faulty Thermal Switch............................................... 245 TROUBLESHOOTING TIPS................................................................ 246 ALTERNATOR.............................................................................. 250 ALTERNATOR REPAIR................................................................... 250 Removal......................................................................... 250 Installation.................................................................... 252 Special Tools and Lubricants.................................................... 252 Epoxy Adhesive.................................................................. 253 Liquid Threadlockers............................................................ 253 Elastoplastic Silicone Resin.................................................... 253 ALTERNATOR EXPLODED VIEW............................................................ 256 ALTERNATOR DISASSEMBLY.............................................................. 258 Regulator Removal............................................................... 258 Fan Removal..................................................................... 259 Pulley Removal.................................................................. 260 Anti-Drive End Housing Removal.................................................. 260 Anti-Drive End Rotor Removal.................................................... 262 Drive End Housing Removal....................................................... 264 Drive End Rotor Removal......................................................... 270 Field Coil Removal.............................................................. 271 Drive End and/or Anti-Drive End Stator Removal.................................. 273 CLEANING AND INSPECTION............................................................. 275 ALTERNATOR ASSEMBLY................................................................. 275 Anti-Drive End Stator Installation.............................................. 275 Drive End Stator Installation................................................... 277 Field Coil Installation......................................................... 280 Drive End Bearing Installation.................................................. 282 Drive End Rotor Installation.................................................... 284 Rotor and Rotor Shaft Installation.............................................. 284 Drive End Housing Installation.................................................. 285 Anti-Drive End Rotor Installation............................................... 289 Anti-Drive End Housing Installation............................................. 290 Regulator Installation.......................................................... 293 THERMAL SWITCH...................................................................... 294 Removal......................................................................... 294 Installation.................................................................... 296 SUPPORT STAND....................................................................... 296 VEHICLE HEALTH MONITORING SYSTEM (VHMS)..................................................... 299 VHMS BASIC FEATURES..................................................................... 299 Gather Data......................................................................... 299 Convert and Record Data............................................................. 300 Communicate Data to Off-Board Systems............................................... 300 USING THE VHMS SYSTEM................................................................... 301 Basic Precautions................................................................... 301 Turning the VHMS System On.......................................................... 301 Normal VHMS Operation............................................................... 302 Turning the VHMS System Off......................................................... 302 Downloading From the VHMS Controller................................................ 302 VHMS DATA ITEMS......................................................................... 303 Fault Codes......................................................................... 303 Machine History..................................................................... 303 VHMS History........................................................................ 304 Snapshots........................................................................... 304 Manual Snapshots.................................................................... 304 Trends.............................................................................. 304 Histogram (Load Map) Data........................................................... 306 Haul Cycle Data..................................................................... 307 Alarm and Snapshot Triggers......................................................... 308 Satellite Features.................................................................. 310 VHMS DIAGNOSTIC FEATURES................................................................ 310 Fault History....................................................................... 310 VHMS LED Digits..................................................................... 310 Light (10) PLM III communication.................................................... 310 Light (11) OrbComm.................................................................. 310 VHMS COMPONENTS............................................................................. 311 VHMS CONTROLLER......................................................................... 311 Removal............................................................................. 312 Installation........................................................................ 312 OrbComm Controller.................................................................. 313 Removal............................................................................. 313 Installation........................................................................ 314 INTERFACE MODULE........................................................................ 314 Inputs.............................................................................. 315 Outputs............................................................................. 315 Removal............................................................................. 315 Installation........................................................................ 315 COMPONENT LOCATION...................................................................... 316 Circuit Breakers.................................................................... 316 Temperature Sensors................................................................. 317 Pressure Sensors.................................................................... 318 SECTION D11 - VHMS COMPONENTS - INDEX........................................................... 297 VHMS SOFTWARE............................................................................... 321 Necessary Software...................................................................... 321 Necessary Tools......................................................................... 322 VHMS TOOL BOX INSTALLATION.............................................................. 322 VHMS SETTING TOOL INSTALLATION.......................................................... 323 VHMS INITIALIZATION PROCEDURE........................................................... 323 Preliminary Checks.................................................................. 323 Initialization Steps................................................................ 323 Select Operation.................................................................... 324 VHMS Setting Function............................................................... 324 Machine Information Setting(1)...................................................... 324 Machine Information Setting(2)...................................................... 324 Date and Time Setting............................................................... 325 GCC Setting......................................................................... 325 Setting Summary..................................................................... 325 VHMS SNAPSHOT PROCEDURE................................................................. 326 VHMS DOWNLOAD........................................................................... 326 VHMS FTP UPLOAD......................................................................... 327 LOCATION OF DOWNLOAD FILES.............................................................. 328 INSTALLING FLASHBURN PROGRAM............................................................ 329 INSTALLING APPLICATION CODE INTO INTERFACE MODULE....................................... 329 INSTALLING REALTIME MONITOR SOFTWARE PROGRAM............................................ 330 WHEN REPLACING A VHMS CONTROLLER........................................................ 330 To Set: Date and time, satellite, payload meter..................................... 332 Review Setting Information.......................................................... 334 SECTION D12 - VHMS SOFTWARE - INDEX............................................................. 319 SECTION D13 - VHMS CHECKOUT AND TROUBLESHOOTING - INDEX......................................... 335 VHMS CHECKOUT AND TROUBLESHOOTING........................................................... 337 VHMS CHECKOUT PROCEDURE................................................................. 337 General............................................................................. 337 Structure and Purpose............................................................... 338 Necessary Equipment:................................................................ 338 VHMS SYSTEM CHECKOUT.................................................................... 338 Preliminary......................................................................... 338 Checking Inputs To The Interface Module............................................. 339 For 930E & 960E trucks only:........................................................ 341 For 830E trucks only:............................................................... 341 Checking Outputs From The Interface Module.......................................... 342 For 830E only:...................................................................... 342 For 930E & 960E only:............................................................... 342 VHMS CONTROLLER CHECKOUT................................................................ 342 TROUBLESHOOTING......................................................................... 343 Communications Networks............................................................. 343 Coaxial Cable....................................................................... 343 VHMS COMPONENTS......................................................................... 344 VHMS Controller..................................................................... 344 OrbComm Controller.................................................................. 345 Interface Module.................................................................... 345 FAULT CODES............................................................................. 346 Fault History....................................................................... 346 VHMS LED Display Fault Codes........................................................ 347 Chassis Fault Codes................................................................. 348 Engine Fault Codes.................................................................. 352 FAULT TREE ANALYSIS..................................................................... 358 Unable to connect to VHMS from laptop PC............................................ 358 Flashing Error Code N4-23 (PLM III Communications Fault)............................ 359 Flashing Error Code N4-22 (Engine Communications Fault)............................. 360 No Data Received By WebCARE......................................................... 361 Coaxial Cable Troubleshooting....................................................... 362 SECTION D14 - VHMS FORMS - INDEX................................................................ 363 VHMS FORMS.................................................................................. 365 VHMS INITIALIZATION CHECK LIST.......................................................... 365 VHMS DATA DOWNLOAD...................................................................... 366 VHMS INITIALIZATION FORM................................................................ 366 VHMS INITIALIZATION CHECK LIST.......................................................... 368 VHMS INITIALIZATION FORM................................................................ 370 SECTION D35 - PAYLOAD METER III - INDEX......................................................... 371 OPERATION SECTION........................................................................... 377 Introduction............................................................................ 377 Data Summary........................................................................ 377 Data Gathering...................................................................... 377 COMPONENT DESCRIPTION................................................................... 378 System Diagram...................................................................... 378 Suspension Pressure Sensors......................................................... 378 Inclinometer........................................................................ 378 Operator Display.................................................................... 378 Operator Switch..................................................................... 379 Speed Input......................................................................... 379 Body-Up Switch...................................................................... 379 Brake Lock Switch................................................................... 379 Payload Meter....................................................................... 379 Communications Ports................................................................ 379 Key Switch Input.................................................................... 380 Payload Meter Power................................................................. 380 Load Lights......................................................................... 380 Wiring and Termination.............................................................. 381 TCI Outputs......................................................................... 381 OPERATOR’S DISPLAY AND SWITCH........................................................... 382 Reading the Speedometer............................................................. 382 Reading the Load Display............................................................ 382 Using the Operator ID............................................................... 382 Using the Load and Ton Counter...................................................... 382 Total Ton Counter................................................................... 382 Total Load Counter.................................................................. 383 Clearing the Counters............................................................... 383 Viewing Live Sensor Data............................................................ 383 Other Display Messages.............................................................. 383 PAYLOAD OPERATION AND CALCULATION....................................................... 384 Description of Haul Cycle States.................................................... 384 Haul Cycle Description.............................................................. 384 Load Calculation.................................................................... 385 Carry Back.......................................................................... 385 Measurement Accuracy................................................................ 385 SOURCES FOR PAYLOAD ERROR............................................................... 385 Payload Error....................................................................... 385 Loading Conditions.................................................................. 386 Pressure Sensors.................................................................... 386 Swingloads.......................................................................... 386 Speed and Distance.................................................................. 386 HAUL CYCLE DATA......................................................................... 386 Haul Cycle Data..................................................................... 387 Haul Cycle Warning Flags............................................................ 388 Frame Torque Data................................................................... 389 Sprung Weight Data.................................................................. 389 Maximum Speed Data.................................................................. 389 Alarm Records....................................................................... 389 Fault Code Data..................................................................... 390 PC SOFTWARE OVERVIEW.................................................................... 391 PC Overview......................................................................... 391 System Configuration................................................................ 391 Installing the PLMIII Software...................................................... 391 DOWNLOADING DATA........................................................................ 392 PLM III SYSTEM CONFIGURATION............................................................ 393 Starting Communications............................................................. 393 Displayed Payload Units............................................................. 393 Time Units.......................................................................... 393 Connection Menu..................................................................... 393 Connecting to the Payload Meter..................................................... 394 Configure the Payload Meter......................................................... 394 Setting the Date and Time........................................................... 394 Setting the Truck Type.............................................................. 395 Setting the Gauge Display Units..................................................... 395 Setting the Frame Serial Number..................................................... 395 Setting the Truck Number............................................................ 395 Setting the Komatsu Distributor..................................................... 395 Setting the Komatsu Customer........................................................ 395 Clean Truck Tare.................................................................... 396 Inclinometer Calibration............................................................ 396 DATA ANALYSIS........................................................................... 397 Creating a Query.................................................................... 397 Sorting on Truck Unit Number........................................................ 397 Sorting on Truck Type............................................................... 397 Sorting on Date Range............................................................... 398 Sorting on Time Range............................................................... 398 Payload Detail Screen............................................................... 399 Creating Reports.................................................................... 399 Summary - One Page Report........................................................... 400 Detailed - Multi-Page Report........................................................ 400 Creating Graphs..................................................................... 401 Exporting Data...................................................................... 401 CSV Export.......................................................................... 401 Compressed.......................................................................... 403 Importing Data...................................................................... 403 Deleting Haul Cycle Records......................................................... 403 Viewing Alarms...................................................................... 404 Deleting Alarm Records.............................................................. 404 TROUBLESHOOTING SECTION..................................................................... 405 TROUBLESHOOTING......................................................................... 405 Viewing Active Alarms............................................................... 405 Real-Time Data Display.............................................................. 405 Testing the Payload Lights.......................................................... 406 Creating Log Files of Inputs........................................................ 406 Daily Inspections................................................................... 406 Periodic Maintenance................................................................ 406 Abnormal Displays at Power-Up....................................................... 407 No Payload Display When Key Switch is Turned On..................................... 408 No Display on Speedometer........................................................... 409 No Display on Operator Display...................................................... 409 No Communications With PC........................................................... 410 Load Lights Don’t Light During Loading.............................................. 411 Load Lights Remain On............................................................... 412 Load Lights Remain On During Dumping................................................ 412 Display Doesn't Clear When The Load Is Dumped....................................... 412 Calibration Problems................................................................ 413 Alarm 1 - Left-Front Pressure High.................................................. 414 Alarm 2 - Left-Front Pressure Low................................................... 414 Troubleshoot Wiring to Left-Front Suspension........................................ 414 Alarm 3 - Right-Front Pressure High................................................. 415 Alarm 4 - Right-Front Pressure Low.................................................. 415 Troubleshoot Wiring to Right-Front Suspension....................................... 415 Alarm 5 - Left-Rear Pressure High................................................... 416 Alarm 6 - Left-Rear Pressure Low.................................................... 416 Troubleshoot Wiring to Left-Rear Suspension......................................... 416 Alarm 7 - Right-Rear Pressure High.................................................. 417 Alarm 8 - Right-Rear Pressure Low................................................... 417 Troubleshoot Wiring to Right-Rear Suspension........................................ 417 Alarm 9 - Inclinometer High......................................................... 418 Alarm 10 - Inclinometer Low......................................................... 418 Troubleshoot Inclinometer Wiring.................................................... 418 Alarm 13 - Body-Up Input Failure.................................................... 419 Alarm 16 - Memory Write Failure..................................................... 420 Alarm 17 - Memory Read Failure...................................................... 420 Alarm 18............................................................................ 421 Alarm 19............................................................................ 421 Alarm 22............................................................................ 421 Operator Switch Doesn't Work........................................................ 422 Alarm 26 - User Switch Fault - SELECT............................................... 422 Alarm 27 - User Switch Fault - SET.................................................. 422 Connector Map....................................................................... 423 Connectors.......................................................................... 424 PLMIII CHECKOUT PROCEDURE................................................................... 425 General Description..................................................................... 425 Tools Required.......................................................................... 425 Checkout Procedure...................................................................... 425 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................. 429 Flashburn Programming............................................................... 429 Confirmation Checklist.............................................................. 431 SECTION E - ELECTRICAL PROPULSION COMPONENTS - INDEX................................................ 433 SECTION E2 - ELECTRICAL PROPULSION COMPONENTS - INDEX........................................... 435 ELECTRICAL PROPULSION COMPONENTS............................................................ 439 GENERAL SYSTEM DESCRIPTION.............................................................. 439 CONTROL SYSTEM.......................................................................... 439 System Operation.................................................................... 440 FL275 Panel......................................................................... 441 CARD REPLACEMENT........................................................................ 442 Removal............................................................................. 442 Installation........................................................................ 442 Card Repair......................................................................... 442 Panel Wiring........................................................................ 442 COMPUTER DESCRIPTION.................................................................... 443 Microprocessor...................................................................... 443 Download Capability................................................................. 443 SOFTWARE................................................................................ 443 Base Monitor Program................................................................ 443 Runtime Monitor Program - OBJ Running Code.......................................... 443 Configuration Software - CFG........................................................ 444 PTU - Portable Test Unit Code....................................................... 444 System Regulation................................................................... 444 Propulsion.......................................................................... 445 Retarding........................................................................... 445 TWO-DIGIT DISPLAY PANEL................................................................. 446 The Coded Number.................................................................... 446 Events.............................................................................. 446 Frames.............................................................................. 447 Windows............................................................................. 447 System Categories................................................................... 447 Limits On Resetting Faults.......................................................... 447 NA Faults........................................................................... 448 Event Sequence...................................................................... 448 Resetting Events.................................................................... 448 Event Descriptions.................................................................. 448 Subcode Descriptions................................................................ 448 2-DIGIT DISPLAY PANEL SUBCODES.......................................................... 456 PORTABLE TEST UNIT (PTU).................................................................... 459 DESCRIPTION............................................................................. 459 Operational Hints................................................................... 459 SOFTWARE INSTALLATION PREPARATION....................................................... 460 HARD DISK SPACE REQUIREMENTS............................................................ 460 SOFTWARE INSTALLATION ON PTU............................................................ 460 PTU/Truck Communication Problems.................................................... 461 THE MAIN MENU........................................................................... 462 Quit Menu........................................................................... 462 PTU Talk To Truck................................................................... 462 View PTU Saved Files................................................................ 462 List Stat Data Files................................................................ 462 Truck Setup (CFG)................................................................... 462 Select Truck Setup.................................................................. 462 Update CFG Version.................................................................. 462 Change PTU Password................................................................. 462 CONFIGURATION (CFG) FILE CONVERSION..................................................... 464 Conversion Procedure................................................................ 464 Convert Old CFG files for New software.............................................. 465 STATEX CONFIGURATION FILES.............................................................. 468 0) Source Directory: . . ........................................................... 468 1) Select A Truck Configuration . . ................................................ 469 2) View Truck Configuration: Data Curves . . ....................................... 470 3) Change/View Serial and Model Numbers . . ........................................ 471 4) View Options . . ................................................................ 471 5) Change/View Truck Specifics . . ................................................. 473 6) Change/View Overspeeds . . ...................................................... 475 7) Save a Truck Configuration, filename: . . ....................................... 476 8) Save Directory: . . ............................................................. 477 CHANGE PTU PASSWORD..................................................................... 478 PROGRAMMING THE TRUCK................................................................... 479 Connect PTU to the Truck............................................................ 479 Select Configuration File........................................................... 479 Activate The PTU Mode............................................................... 479 Check Object Code Version........................................................... 480 Download Configuration Files........................................................ 481 Date And Time....................................................................... 482 Event Data.......................................................................... 483 Statistical Data.................................................................... 485 View Counters....................................................................... 485 View Profiles....................................................................... 485 Upload Statistical Data To A File................................................... 485 Statistical Data Codes - Counters................................................... 486 STATISTICAL DATA CODES - COUNTERS....................................................... 487 STATISTICAL DATA CODES - PROFILES....................................................... 492 TRUCK SPECIFIC INFORMATION.............................................................. 496 Temporary Truck Settings............................................................ 497 MISCELLANEOUS FEATURES.................................................................. 498 Saving Data......................................................................... 498 PTU Abbreviations................................................................... 499 Other Menu Selections............................................................... 499 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS.............................................. 500 ALTERNATOR.............................................................................. 500 ELECTRIC WHEEL MOTORS................................................................... 500 RETARDING GRIDS......................................................................... 500 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 500 Removal............................................................................. 500 Installation........................................................................ 500 Disassembly......................................................................... 501 Reassembly.......................................................................... 501 COOLING BLOWER WARNING SYSTEM........................................................... 501 Operation........................................................................... 501 Test................................................................................ 501 Removal............................................................................. 502 Installation........................................................................ 502 ELECTRICAL CONTROL CABINET.................................................................. 503 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS...................................... 508 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III.......................................... 509 SECTION E3 - STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE - INDEX............................ 511 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE............................................. 515 GENERAL INFORMATION..................................................................... 515 COMMUNICATIONS PORT CHECK............................................................... 516 PTU Hookup.......................................................................... 516 4.0 SEQUENCE TESTS - (ENGINE NOT ON).................................................... 517 Preparation and Setup............................................................... 517 CONTROL SYSTEM SELF-TEST............................................................ 518 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT............................................ 518 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT.............................................. 519 PTU Setup....................................................................... 519 4.3 REVERSER AND PROPULSION CONTACTORS CHECK........................................ 520 4.4 NOT USED........................................................................ 521 4.5 RETARD CONTACTORS OPERATION CHECK............................................... 521 4.6 GROUND FAULT SENSING CHECK...................................................... 521 4.7 GROUND FAULT IN RETARD OPERATION CHECK.......................................... 522 4.8 OVERRIDE OPERATION CHECK........................................................ 522 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK............................................... 523 4.10 OVERSPEED RETARD OPERATION CHECK............................................... 523 4.11 HOIST INTERLOCK OPERATION CHECK................................................ 524 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK....................................... 524 Return to Main Menu............................................................. 524 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL................................ 525 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU................................... 525 5.2 DIGITAL INPUT CHECKS............................................................ 526 5.3 DIGITAL OUTPUT CHECKS........................................................... 527 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL........................................ 531 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU........................................ 531 6.2 ANALOG INPUT CHECKS............................................................. 532 6.3 FREQUENCY INPUT CHECKS.......................................................... 536 Return to Main Menu............................................................. 537 7.0 SPEED EVENT CHECKS.................................................................. 537 Preparation and Setup............................................................... 537 Setup PTU........................................................................... 537 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK......................... 538 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK.............. 538 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK............. 538 7.4 OTHER SPEED EVENTS CHECKS....................................................... 538 Return to Main Menu............................................................. 538 8.0 RETARD SPEED CONTROL SYSTEM CHECK................................................... 539 Preparation and Setup............................................................... 539 Setup PTU........................................................................... 539 8.1 OVERSPEED PICKUP AND DROPOUT CHECK.............................................. 539 8.2 RETARD POT MAXIMUM SETTING CHECK................................................ 539 8.3 RETARD POT MINIMUM SETTING CHECK................................................ 539 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL.............................. 540 Return to Main Menu............................................................. 540 9.0 LOAD TEST USING TRUCK RETARD GRIDS.................................................. 540 Setup and Preparation............................................................... 540 PTU Setup........................................................................... 540 9.1 LOAD TEST....................................................................... 541 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING............................................. 541 Setup PTU........................................................................... 541 10.1 RETARD CHECK................................................................... 542 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT........................................ 543 11.1 BRAKE SYSTEM INTERLOCKS CHECK.................................................. 543 Preparation..................................................................... 543 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT......................................... 543 11.3 SYNC TRANSFORMER CHECKOUT...................................................... 544 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT..................................... 544 11.5 BATTERY BOOST ADJUSTMENT....................................................... 544 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST.................................... 544 11.7 MOTOR ROTATION TEST............................................................ 545 11.8 GROUND FAULT CHECKS............................................................ 545 12.0 MISCELLANEOUS CHARTS............................................................... 546 12.1 WHEEL MOTOR GEAR RATIOS........................................................ 546 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS................................................. 547 12.3 ENGINE OPTIONS................................................................. 548 SECTION G - DRIVE AXLE, SPINDLE AND WHEELS - INDEX.................................................. 549 SECTION G2 - TIRES AND RIMS - INDEX............................................................. 551 TIRES AND RIMS.............................................................................. 553 GENERAL INFORMATION..................................................................... 553 TIRES................................................................................... 553 Handling Tires...................................................................... 553 Tire Maintenance.................................................................... 554 Storing Tires After Removal......................................................... 554 FRONT TIRES AND RIMS.................................................................... 555 Removal............................................................................. 555 Installation........................................................................ 556 REAR TIRES AND RIMS..................................................................... 557 Removal............................................................................. 557 Installation........................................................................ 558 RIM................................................................................. 559 Tire Removal........................................................................ 559 RIM AND TIRE PREPARATION................................................................ 560 LUBRICANTS.............................................................................. 560 TIRE INSTALLATION....................................................................... 561 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX................................................ 563 FRONT WHEEL HUB AND SPINDLE................................................................. 565 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 565 Removal............................................................................. 565 Installation........................................................................ 567 Disassembly......................................................................... 568 Cleaning and Inspection............................................................. 569 Assembly............................................................................ 569 Wheel Bearing Adjustment (Spindle Vertical)......................................... 572 Wheel Bearing Adjustment (Tire Mounted)............................................. 573 STEERING CYLINDERS AND TIE ROD.......................................................... 574 Spherical Bearing Wear Limits....................................................... 574 Removal............................................................................. 575 Installation........................................................................ 577 Bearing Replacement................................................................. 577 TOE-IN ADJUSTMENT....................................................................... 578 SECTION G4 - REAR AXLE HOUSING - INDEX.......................................................... 579 REAR AXLE HOUSING........................................................................... 581 PIVOT PIN............................................................................... 581 Removal............................................................................. 581 Installation........................................................................ 582 PIVOT EYE BEARING....................................................................... 582 Disassembly......................................................................... 582 Assembly............................................................................ 583 PIVOT EYE REPAIR........................................................................ 583 Removal............................................................................. 583 Disassembly......................................................................... 583 Bushing (New)....................................................................... 583 Pivot Eye Bore (New)................................................................ 583 Assembly............................................................................ 583 Installation........................................................................ 584 ANTI-SWAY BAR........................................................................... 584 Removal............................................................................. 584 Installation........................................................................ 584 Disassembly......................................................................... 585 Cleaning and Inspection............................................................. 585 Assembly............................................................................ 585 SECTION G5 - REAR AXLE HOUSING - INDEX.......................................................... 587 REAR AXLE HOUSING........................................................................... 589 REAR AXLE HOUSING....................................................................... 589 Removal............................................................................. 589 Installation........................................................................ 589 WHEEL MOTOR............................................................................. 589 Removal............................................................................. 589 Cleaning and Inspection............................................................. 590 Installation........................................................................ 590 Maximum Cap Screw Usage............................................................. 590 REAR AXLE HOUSING BUMPER PAD............................................................ 591 SECTION H - SUSPENSIONS - INDEX..................................................................... 593 SECTION H2 - FRONT SUSPENSION - INDEX........................................................... 595 FRONT SUSPENSION............................................................................ 597 Removal................................................................................. 597 Installation............................................................................ 599 Turn-of-the-Nut Tightening Procedure.................................................... 600 Disassembly............................................................................. 601 Cleaning and Inspection................................................................. 602 Assembly (Bearing Only)................................................................. 602 Suspension Assembly (Complete).......................................................... 602 SUSPENSION PRESSURE TEST................................................................ 604 SECTION H3 - REAR SUSPENSIONS - INDEX........................................................... 607 REAR SUSPENSIONS............................................................................ 609 Removal................................................................................. 610 Installation............................................................................ 612 Disassembly............................................................................. 612 Cleaning and Inspection................................................................. 612 Assembly................................................................................ 613 SUSPENSION PRESSURE TEST................................................................ 615 SECTION H4 - OILING AND CHARGING PROCEDURES - INDEX............................................. 617 OILING AND CHARGING PROCEDURE............................................................... 619 GENERAL................................................................................. 619 EQUIPMENT LIST.......................................................................... 619 Hydrair® Charging Kit............................................................... 619 Installation of Charging Kit........................................................ 619 Removal of Charging Kit............................................................. 620 Support Blocks For Oiling and Charging Dimensions................................... 620 FRONT SUSPENSION........................................................................ 621 Front Suspension Oiling............................................................. 621 Front Suspension Nitrogen Charging.................................................. 622 REAR SUSPENSION......................................................................... 624 Rear Suspension Oiling.............................................................. 624 Rear Suspension Nitrogen Charging................................................... 626 OIL AND NITROGEN SPECIFICATIONS CHART....................................................... 627 SECTION J - BRAKE CIRCUIT - INDEX................................................................... 629 SECTION J2 - BRAKE CIRCUIT - INDEX.............................................................. 631 BRAKE CIRCUIT............................................................................... 633 GENERAL DESCRIPTION..................................................................... 633 SERVICE BRAKE CIRCUIT................................................................... 633 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 635 PARKING BRAKE CIRCUIT................................................................... 635 Normal Operation (key switch on, engine on)......................................... 635 BRAKE LOCK CIRCUIT...................................................................... 636 WARNING CIRCUIT......................................................................... 636 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX............................................ 639 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 641 BRAKE VALVE............................................................................. 641 Rebuild Criteria.................................................................... 641 Removal............................................................................. 641 Installation........................................................................ 643 Disassembly......................................................................... 645 Cleaning and Inspection............................................................. 647 ASSEMBLY................................................................................ 647 Actuator Base Threaded Inserts...................................................... 647 Boot and Cap........................................................................ 647 Valve Body Seal Installation........................................................ 648 Regulator Sleeve O-Ring Installation................................................ 649 Actuator Plunger O-Ring Installation................................................ 649 Assembly of Valve................................................................... 649 DIFFERENTIAL PRESSURE SWITCH............................................................ 650 Disassembly......................................................................... 651 Cleaning and Inspection............................................................. 651 Assembly............................................................................ 651 VALVE BENCH TEST AND ADJUSTMENT......................................................... 651 Test Set Up Procedure............................................................... 653 Brake Valve Output Pressure Adjustment.............................................. 653 Differential Pressure Switch Test................................................... 654 Final Test and Adjustment........................................................... 654 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 655 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (DUAL FUNCTION PEDAL).... 657 Installation of Retard Pedal To Brake Pedal......................................... 657 HYDRAULIC BRAKE ACCUMULATORS............................................................ 658 Brake Accumulator Bleed-Down Procedure.............................................. 658 Removal............................................................................. 658 Installation........................................................................ 660 Disassembly......................................................................... 660 Cleaning and Inspection............................................................. 662 Assembly............................................................................ 662 Leak Testing........................................................................ 664 BRAKE ACCUMULATOR CHARGING.............................................................. 665 Temperature During Precharge........................................................ 667 ACCUMULATOR STORAGE..................................................................... 668 Installation........................................................................ 668 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 671 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX.......................................... 671 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 673 EQUIPMENT REQUIRED...................................................................... 676 INITIAL SYSTEM SET-UP................................................................... 677 Parking Brake....................................................................... 677 Service Brakes...................................................................... 678 Brake Lock/Secondary................................................................ 678 Low Brake Pressure and Auto Apply................................................... 679 Reapplications...................................................................... 679 Differential Pressure Switch........................................................ 679 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 681 CHECK-OUT PROCEDURE......................................................................... 684 HYDRAULIC BRAKE SYSTEM DATA SHEET........................................................... 684 SECTION J5 - FRONT DISC BRAKES- INDEX........................................................... 687 FRONT DISC BRAKES........................................................................... 689 BRAKE CALIPER........................................................................... 689 Removal............................................................................. 689 Installation........................................................................ 690 Disassembly......................................................................... 691 Cleaning and Inspection............................................................. 691 Assembly............................................................................ 693 BRAKE LINING............................................................................ 693 Replacement......................................................................... 693 FRONT SERVICE BRAKE BURNISHING.......................................................... 695 BRAKE BLEEDING PROCEDURE............................................................ 696 REAR DISC BRAKES............................................................................ 699 REAR BRAKES............................................................................. 699 CALIPER, DISC, AND PARKING BRAKE........................................................ 699 Removal............................................................................. 699 Installation........................................................................ 700 Trucks equipped with one-piece adapter.............................................. 703 Removal............................................................................. 703 Installation........................................................................ 704 CALIPER PISTON.......................................................................... 705 Piston Assembly Removal............................................................. 705 Inspection.......................................................................... 705 Piston Assembly Installation........................................................ 706 FUNCTIONAL TEST OF PISTON ASSEMBLY...................................................... 707 Return Spring Force................................................................. 707 Built-In Clearance.................................................................. 707 Grip Force.......................................................................... 708 Grip Force Measurement.............................................................. 710 Spring Force Measurement............................................................ 711 Disassembly of Piston Assembly...................................................... 712 Assembly of Piston Assembly......................................................... 713 BENCH TEST.............................................................................. 713 BRAKE LINING............................................................................ 714 Replacement......................................................................... 714 SERVICE BRAKE BURNISHING................................................................ 717 SAFETY PRECAUTIONS.................................................................. 717 Rear Brake Conditioning......................................................... 718 BRAKE BLEEDING PROCEDURE............................................................ 719 Spring Force Measurement........................................................ 720 SECTION J6 - REAR BRAKES - INDEX................................................................ 697 SECTION J7 - PARKING BRAKE - INDEX.............................................................. 721 PARKING BRAKE............................................................................... 723 GENERAL INFORMATION..................................................................... 723 PARKING BRAKE CALIPER................................................................... 723 Lining Thickness Inspection......................................................... 723 Removal............................................................................. 724 Installation........................................................................ 724 Parking Brake Adjustment............................................................ 725 Parking Brake Caliper Disassembly................................................... 726 Cleaning and Inspection............................................................. 727 Parking Brake Caliper Assembly...................................................... 728 PARKING BRAKE LINING REPLACEMENT........................................................ 728 PARKING BRAKE BURNISH PROCEDURE......................................................... 728 Lining Conditioning................................................................. 728 BRAKE BLEEDING PROCEDURE................................................................ 729 HYDRAULIC SYSTEM............................................................................ 731 SECTION L - HYDRAULIC SYSTEM - INDEX................................................................ 731 SECTION L2 - HYDRAULIC SYSTEM - INDEX........................................................... 733 HYDRAULIC SYSTEM............................................................................ 735 GENERAL INFORMATION..................................................................... 735 HYDRAULIC SYSTEMS OPERATION............................................................. 735 Hoist Circuit Operation............................................................. 735 Steering Circuit Operation.......................................................... 737 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX.......................................... 741 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 743 HOIST PUMP.............................................................................. 743 Removal............................................................................. 743 Installation........................................................................ 744 Disassembly......................................................................... 745 Inspection of Parts................................................................. 748 Assembly............................................................................ 748 Troubleshooting Guide............................................................... 752 HYDRAULIC TANK.......................................................................... 753 Filling Instructions................................................................ 753 Removal............................................................................. 754 Installation........................................................................ 754 HYDRAULIC TANK STRAINER AND DIFFUSER.................................................... 754 Removal............................................................................. 754 Inspect and Clean................................................................... 755 Installation........................................................................ 755 SECTION L4 - STEERING CIRCUIT - INDEX........................................................... 757 STEERING CIRCUIT............................................................................ 759 STEERING CIRCUIT OPERATION.............................................................. 759 COMPONENT DESCRIPTION................................................................... 760 Steering Control Valve.............................................................. 760 Unloader Valve...................................................................... 761 Bleed-Down Manifold Valve........................................................... 761 Flow Amplifier...................................................................... 767 FLOW AMPLIFIER SYSTEM OPERATION......................................................... 768 No Steer............................................................................ 768 Steering Left....................................................................... 770 Steering Right...................................................................... 772 No Steer, External Shock Load....................................................... 774 Steering Pump....................................................................... 776 High Pressure Filter................................................................ 776 Accumulators........................................................................ 776 Low Precharge Warning Switch........................................................ 776 SECTION L5 - STEERING CONTROL UNIT - INDEX...................................................... 777 STEERING CONTROL UNIT....................................................................... 779 GENERAL INFORMATION..................................................................... 779 Removal............................................................................. 779 Installation........................................................................ 779 STEERING CONTROL UNIT REBUILD........................................................... 781 Disassembly......................................................................... 781 Cleaning and Inspection............................................................. 782 Assembly............................................................................ 784 STEERING/BRAKE PUMP..................................................................... 787 Removal............................................................................. 787 Installation........................................................................ 787 Disassembly......................................................................... 789 Inspection of Parts................................................................. 790 Assembly............................................................................ 790 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX.......................................... 793 STEERING CIRCUIT COMPONENT REPAIR........................................................... 795 BLEED-DOWN MANIFOLD..................................................................... 795 Removal............................................................................. 795 Installation........................................................................ 795 ACCUMULATOR............................................................................. 796 Removal............................................................................. 796 Installation........................................................................ 797 Disassembly......................................................................... 798 Cleaning and Inspection............................................................. 798 Assembly............................................................................ 798 Leak Testing........................................................................ 799 STEERING ACCUMULATOR CHARGING........................................................... 801 Temperature During Precharge........................................................ 804 ACCUMULATOR STORAGE..................................................................... 804 Installation........................................................................ 805 FLOW AMPLIFIER.......................................................................... 806 Removal............................................................................. 806 Installation........................................................................ 806 Disassembly......................................................................... 806 Assembly............................................................................ 809 STEERING CYLINDERS...................................................................... 810 Disassembly......................................................................... 810 Piston Seal and Bearing Installation................................................ 810 Cylinder Assembly................................................................... 810 Test................................................................................ 811 TROUBLESHOOTING CHART....................................................................... 813 SECTION L7 - HOIST CIRCUIT - INDEX.............................................................. 817 HOIST CIRCUIT............................................................................... 819 HOIST CIRCUIT OPERATION................................................................. 819 COMPONENT DESCRIPTION................................................................... 820 Hydraulic Tank...................................................................... 820 Hydraulic Pump...................................................................... 820 High Pressure Filter................................................................ 820 Hoist Valve......................................................................... 820 Hoist Pilot Valve................................................................... 821 Bleed-Down Manifold................................................................. 822 Counterbalance Manifold............................................................. 822 Hoist-Up Limit Solenoid............................................................. 822 Pilot Operated Check Valve.......................................................... 822 HOIST VALVE OPERATION................................................................... 823 Float Operation..................................................................... 823 Power Up Operation (Figure 7-5)..................................................... 825 Hold Operation (Figure 7-6)......................................................... 827 Power Down Operation (Figure 7-7)................................................... 829 Float Operation (Figure 7-8)........................................................ 831 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX............................................. 833 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 835 HOIST VALVE............................................................................. 835 Removal............................................................................. 835 Installation........................................................................ 835 O-Ring Replacement.................................................................. 837 INLET SECTION........................................................................... 838 Disassembly......................................................................... 838 Cleaning and Inspection............................................................. 839 Assembly............................................................................ 839 REAR SPOOL SECTION (WORK PORTS)......................................................... 840 Disassembly......................................................................... 840 Cleaning and Inspection............................................................. 842 Assembly............................................................................ 842 HOIST PILOT VALVE....................................................................... 844 Removal............................................................................. 844 Installation........................................................................ 844 Disassembly......................................................................... 845 Cleaning and Inspection............................................................. 846 Assembly............................................................................ 846 HOIST UP LIMIT SOLENOID VALVE........................................................... 847 HOIST CYLINDERS......................................................................... 847 Removal............................................................................. 847 Installation........................................................................ 848 Disassembly......................................................................... 851 Cleaning and Inspection............................................................. 852 SS1143 Tightening Tool - Assembly Drawing........................................... 853 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 853 Quill Installation.................................................................. 853 Installation Of Check Balls And Plugs In Quill...................................... 854 Assembly of Cylinder................................................................ 856 COUNTERBALANCE MANIFOLD................................................................. 857 SECTION L9 - HIGH PRESSURE FILTERS - INDEX...................................................... 859 HYDRAULIC SYSTEM FILTERS.................................................................... 861 HOIST CIRCUIT FILTER.................................................................... 861 Filter Element Replacement.......................................................... 861 Removal............................................................................. 862 Installation........................................................................ 862 Indicator Switch.................................................................... 862 STEERING CIRCUIT FILTER................................................................. 863 Filter Element Replacement.......................................................... 863 Removal............................................................................. 864 Installation........................................................................ 864 Indicator Switch.................................................................... 864 INDICATOR SWITCH........................................................................ 864 Test Procedure...................................................................... 864 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX............................................. 867 HYDRAULIC CHECK-OUT PROCEDURE............................................................... 869 INITIAL START UP AND FLUSHING........................................................... 869 COMPONENT CHECKOUT AND ADJUSTMENT....................................................... 871 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE........................... 873 Counterbalance Valve Adjustment..................................................... 875 Manifold Assembly................................................................... 875 OIL CLEANLINESS CHECK................................................................... 875 Oil Sampling Location On Truck...................................................... 875 Oil Sampling Process and Cleanliness Criteria....................................... 876 DISABLED TRUCK DUMPING PROCEDURE........................................................ 876 Hookup.............................................................................. 876 Raising the Body.................................................................... 876 Lowering the Body................................................................... 877 Troubleshooting Chart............................................................... 878 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX....................................................... 885 SECTION M7 - ENGINE OIL HEATERS - INDEX......................................................... 887 ENGINE OIL HEATERS.......................................................................... 889 GENERAL INFORMATION..................................................................... 889 TROUBLESHOOTING......................................................................... 889 HEATER ELEMENT.......................................................................... 889 Removal............................................................................. 889 Installation........................................................................ 890 SECTION M8 - SPECIAL TOOLS...................................................................... 891 SECTION N - OPERATOR'S CAB - INDEX.................................................................. 901 SECTION N2 - TRUCK CAB - INDEX.................................................................. 903 TRUCK CAB................................................................................... 905 TRUCK CAB............................................................................... 905 Description......................................................................... 905 Removal............................................................................. 906 Installation........................................................................ 908 CAB DOOR................................................................................ 908 Removal............................................................................. 908 Installation........................................................................ 909 Door Adjustment..................................................................... 909 Door Jam Bolt Adjustment............................................................ 909 Door Handle Plunger Adjustment...................................................... 911 Replace Door Glass.................................................................. 912 Replace Door Window Regulator....................................................... 916 Replace Door Handle or Latch Assembly............................................... 916 Door and Door Hinge Seal Replacement................................................ 917 Door Opening Seal Removal........................................................... 917 Installation........................................................................ 917 GLASS REPLACEMENT....................................................................... 918 Adhesive-Bonded Windows............................................................. 918 Recommended Tools/Supplies.......................................................... 918 Replacement Procedure............................................................... 918 Windshield and Rear Glass........................................................... 919 Removal............................................................................. 919 Installation........................................................................ 920 SECTION N3 - CAB COMPONENTS - INDEX............................................................. 921 CAB COMPONENTS.............................................................................. 923 WINDSHIELD WIPERS....................................................................... 923 WIPER MOTOR REPLACEMENT............................................................. 923 Removal......................................................................... 923 Installation.................................................................... 923 WIPER ARM REPLACEMENT............................................................... 923 Removal......................................................................... 923 Installation.................................................................... 924 WIPER LINKAGE REPLACEMENT........................................................... 924 Removal......................................................................... 924 Installation.................................................................... 925 WINDSHIELD WASHER................................................................... 925 Operation....................................................................... 925 Service......................................................................... 925 SECTION N4 - OPERATOR COMFORT - INDEX........................................................... 927 HEATER/AIR CONDITIONER...................................................................... 929 CONTROLS................................................................................ 929 Operation........................................................................... 929 Heater/Air Conditioner Vents........................................................ 929 Defroster Vent Control Switch....................................................... 929 Heat Control Switch................................................................. 929 Temperature Control Knob............................................................ 929 Fan Control Knob.................................................................... 929 Heater/Air Conditioner Selector Switch.............................................. 929 COMPONENTS.............................................................................. 930 Circuit Breakers.................................................................... 930 Relays.............................................................................. 930 Heater Core......................................................................... 930 Fan Motor and Speed Control......................................................... 931 Test................................................................................ 931 Actuators........................................................................... 931 Test................................................................................ 931 Cab Air Filter...................................................................... 932 AIR CONDITIONING SYSTEM..................................................................... 934 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................... 935 PRINCIPLES OF REFRIGERATION............................................................. 935 Air Conditioning.................................................................... 935 Refrigeration - The Act of Cooling.................................................. 936 The Refrigeration Cycle............................................................. 936 AIR CONDITIONER SYSTEM COMPONENTS....................................................... 937 Compressor (Refrigerant Pump)....................................................... 937 Service Valves...................................................................... 937 Receiver-Drier...................................................................... 937 Condenser........................................................................... 937 Expansion Block Valve............................................................... 938 Accumulator......................................................................... 938 Evaporator.......................................................................... 939 ELECTRICAL CIRCUIT...................................................................... 939 Thermostat.......................................................................... 939 Compressor Clutch................................................................... 940 Trinary™ Switch..................................................................... 940 SYSTEM SERVICING........................................................................ 942 SERVICE TOOLS AND EQUIPMENT............................................................. 943 Recovery/Recycle Station............................................................ 943 Leak Detector....................................................................... 944 Service Valves...................................................................... 944 Vacuum Pump......................................................................... 944 Manifold Gauge Set.................................................................. 945 Low Side Gauge...................................................................... 945 High Side Gauge..................................................................... 945 Installing Manifold Gauge Set....................................................... 946 Purging Air From Service Hoses...................................................... 946 SYSTEM PERFORMANCE TEST................................................................. 947 SYSTEM OIL.............................................................................. 948 Handling and Reusing RPAG Oil....................................................... 948 Oil Quantity........................................................................ 948 Checking System Oil................................................................. 948 REFRIGERANT............................................................................. 949 Recycled Refrigerant................................................................ 949 Reclaimed Refrigerant............................................................... 949 Refrigerant Quantity................................................................ 950 R-134a Refrigerant Containers....................................................... 950 SYSTEM LEAK TESTING..................................................................... 950 Electronic Leak Detector............................................................ 951 Tracer Dyes......................................................................... 951 Soap and Water...................................................................... 951 RECOVERING AND RECYCLING THE REFRIGERANT................................................ 952 Performing the Recovery Cycle....................................................... 952 Performing the Recycling Procedure.................................................. 952 Evacuating and Charging the A/C System.............................................. 952 SYSTEM REPAIR........................................................................... 953 System Flushing..................................................................... 953 COMPONENT REPLACEMENT................................................................... 954 Hoses and Fittings.................................................................. 954 Lines............................................................................... 954 Expansion Valve..................................................................... 954 Receiver-Drier...................................................................... 954 Thermostat.......................................................................... 954 Compressor.......................................................................... 955 Accumulator......................................................................... 955 Clutch.............................................................................. 955 Servicing the Compressor Clutch..................................................... 956 Pulley Removal...................................................................... 958 Clutch Coil Check................................................................... 959 Pulley Installation................................................................. 959 Clutch Assembly Installation........................................................ 960 EVACUATING THE SYSTEM................................................................... 961 CHARGING THE A/C SYSTEM................................................................. 963 AIR CONDITIONER DRIVE BELT.............................................................. 964 Pulley Alignment.................................................................... 964 Belt Tension........................................................................ 965 TROUBLESHOOTING......................................................................... 966 Preliminary Checks.................................................................. 966 Diagnosis of Gauge Readings and System Performance.................................. 966 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.......................................... 967 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM........................................ 973 SECTION N5 - OPERATOR CONTROLS AND EQUIPMENT - INDEX............................................ 975 OPERATOR CONTROLS AND EQUIPMENT............................................................. 977 STEERING WHEEL AND CONTROLS............................................................. 978 STEERING WHEEL...................................................................... 978 HORN BUTTON......................................................................... 978 TILT/TELESCOPE LEVER................................................................ 978 M ULTI-FUNCTION TURN SIGNAL SWITCH.................................................. 978 Turn Signal Operation........................................................... 978 High Beam Headlight Operation................................................... 979 Windshield Wiper Operation...................................................... 979 STEERING COLUMN..................................................................... 979 Removal......................................................................... 979 Inspection...................................................................... 980 Installation.................................................................... 980 PEDALS.................................................................................. 980 SERVICE BRAKE PEDAL................................................................. 980 DYNAMIC RETARDER PEDAL.............................................................. 980 Optional - Dual Function/Single Pedal........................................... 981 THROTTLE PEDAL...................................................................... 981 OVERHEAD PANEL CONTROLS AND COMPONENTS.................................................. 982 GRADE/SPEED WARNING CHART........................................................... 982 RADIO SPEAKERS...................................................................... 982 WARNING ALARM BUZZER................................................................ 982 CAB RADIO........................................................................... 982 WARNING LIGHTS DIMMER CONTROL....................................................... 982 WARNING/STATUS INDICATOR LIGHT PANEL................................................ 982 AIR CLEANER VACUUM GAUGES........................................................... 982 WINDSHIELD WIPERS................................................................... 982 TRUCK CONTROLS...................................................................... 983 F-N-R Selector Switch........................................................... 983 Hoist Control Lever............................................................. 984 CONSOLE SWITCHES AND CONTROLS....................................................... 984 Ashtray......................................................................... 984 Cigarette Lighter............................................................... 984 Left-Hand Window Control Switch................................................. 984 Right-Hand Window Control Switch................................................ 984 Engine Shutdown Switch.......................................................... 984 Override Switch................................................................. 984 Retard Speed Control (RSC) Switch............................................... 985 Retard Speed Control (RSC) Dial................................................. 985 Statex III Download Port........................................................ 985 Engine Diagnostic Port (CENSE).................................................. 986 Modular Mining Port............................................................. 986 Passenger Seat.................................................................. 986 Engine Diagnostic Connectors.................................................... 986 Engine Diagnostics Connector.................................................... 986 Data Storage Button............................................................. 986 PAYLOAD METER....................................................................... 986 Payload Meter Download Connector................................................ 986 CAB CLIMATE CONTROL..................................................................... 987 HEATER/AIR CONDITIONER VENTS........................................................ 987 HEATER/AIR CONDITIONER CONTROLS AND VENTS........................................... 987 Defroster Vent Control Switch................................................... 987 Heat Control Switch............................................................. 987 Temperature Control Knob........................................................ 987 Fan Control Knob................................................................ 987 Heater/Air Conditioner Vents.................................................... 987 OPERATOR SEAT........................................................................... 988 ADJUSTMENT.......................................................................... 988 INSTRUMENT PANEL........................................................................ 989 CONTROL SYMBOLS..................................................................... 989 CONTROL SWITCHES AND GAUGES......................................................... 990 Key Switch...................................................................... 991 Engine Shutdown Switch With Timer Delay......................................... 991 Fog Light Switch................................................................ 991 Ladder Light Switch............................................................. 991 Backup Light Switch............................................................. 991 Panel Illumination Lights....................................................... 991 Cab Air Conditioner/Heater Vents................................................ 991 Engine Cold Weather Starting Aid Switch......................................... 992 Rotating Beacon Light Switch.................................................... 992 Heated Mirror Switch............................................................ 992 Wheel Brake Lock Switch......................................................... 992 Parking Brake Switch............................................................ 992 Digital Tachometer.............................................................. 993 Right Turn Signal Indicator Light............................................... 993 High Beam Headlight Indicator Light............................................. 993 Left Turn Signal Indicator Light................................................ 993 Digital Speedometer/Payload Meter Display....................................... 993 Voltmeter Gauge................................................................. 993 Engine Oil Pressure Gauge....................................................... 993 Engine Water Temperature Gauge.................................................. 993 Fuel Gauge...................................................................... 994 Engine Hourmeter................................................................ 994 Headlight Switch................................................................ 994 Panel Illumination Lights Dimmer Rheostat....................................... 994 Payload Meter Switch............................................................ 994 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL........................................... 995 DESCRIPTION OF INDICATOR SYMBOLS.................................................... 995 INDICATOR LIGHT FUNCTIONS........................................................... 996 High Hydraulic Oil Temperature.................................................. 996 Low Steering Pressure........................................................... 996 Low Accumulator Precharge Pressure Warning...................................... 996 Electric System Fault Warning................................................... 997 Low Brake Pressure Indicator.................................................... 997 Low Hydraulic Tank Level........................................................ 997 Low Automatic Lubrication System Pressure....................................... 997 Circuit Breaker Tripped......................................................... 997 Hydraulic Oil Filter............................................................ 997 Low Fuel Indicator.............................................................. 998 Parking Brake Indicator......................................................... 998 Service Brake Indicator......................................................... 998 Body Up Indicator............................................................... 998 Dynamic Retarding Indicator..................................................... 998 Stop Engine Warning............................................................. 998 Backup Indicator................................................................ 998 Engine Shutdown Timer Switch- Five Minute Idle.................................. 998 Retard Speed Control............................................................ 999 Service Engine Indicator (AEM).................................................. 999 High Wheel Motor Temperature Indicator.......................................... 999 Blower Fault Warning............................................................ 999 Service Engine Indicator (CENSE)................................................ 999 Komatsu Engines w/Centry™ Fuel Control.......................................... 999 Hazard Warning Light Switch.....................................................1000 Lamp Test Switch/Centry™ Diagnostic Test Switch.................................1000 CENTRY™ FUEL SYSTEM DIAGNOSTICS.........................................................1000 GENERAL OPERATION...................................................................1000 DETERMINING FAULT CODES.............................................................1000 EXITING THE DIAGNOSTICS MODE........................................................1002 VEHICLE HEALTH MONITORING SYSTEM (VHMS).................................................1002 BASIC PRECAUTIONS...................................................................1002 OPERATION...........................................................................1002 INTERFACE MODULE....................................................................1004 SECTION P - LUBRICATION AND SERVICE - INDEX.........................................................1005 SECTION P2 - LUBRICATION AND SERVICE - INDEX....................................................1007 LUBRICATION AND SERVICE.....................................................................1009 GENERAL INFORMATION.....................................................................1009 HYDRAULIC TANK SERVICE..................................................................1009 Adding Oil..........................................................................1009 COOLING SYSTEM..........................................................................1010 Coolant Level Check.................................................................1010 Radiator Filling Procedure..........................................................1010 Antifreeze Temperature Recommendations..............................................1010 50 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................................1014 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................1014 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................1015 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................1018 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................1020 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................1021 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................1022 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................1023 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................1023 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX...............................................1025 AUTOMATIC LUBRICATION SYSTEM................................................................1027 GENERAL DESCRIPTION.....................................................................1027 SYSTEM COMPONENTS.......................................................................1028 Filter Assembly.....................................................................1028 Hydraulic Motor and Grease Pump.....................................................1028 Reservoir...........................................................................1029 Fixed Pressure Reducing Valve.......................................................1029 Flow Control Valve..................................................................1029 Solenoid Valve......................................................................1029 Vent Valve..........................................................................1029 24VDC Lubrication Cycle Timer.......................................................1029 Time Delay Module...................................................................1029 Pump Cutoff Pressure Switch.........................................................1029 Unloader Valve......................................................................1029 Pressure Switch.....................................................................1029 Pressure Gauge......................................................................1031 Manual Override Button..............................................................1031 Injectors...........................................................................1031 SYSTEM OPERATION........................................................................1033 Normal Operation....................................................................1033 Pressure Failure Detection Circuits.................................................1034 GENERAL INSTRUCTIONS........................................................................1035 LUBRICANT REQUIRED FOR SYSTEM...........................................................1035 SYSTEM PRIMING..........................................................................1035 LUBRICANT PUMP..........................................................................1036 Pump Housing Oil Level..............................................................1036 Pump Pressure Control...............................................................1036 FILTER AND RESERVOIR....................................................................1036 Filter Assembly Element.............................................................1037 INJECTORS (SL-1 Series H)...............................................................1037 Injector Specifications.............................................................1037 Injector Adjustment.................................................................1037 INJECTOR OPERATION..........................................................................1039 SYSTEM CHECKOUT.........................................................................1040 Lubrication Cycle Timer Check.......................................................1040 Lubrication Cycle Timer Adjustment..................................................1041 PREVENTIVE MAINTENANCE INSPECTION.......................................................1041 10 Hour Lubrication System Inspection...............................................1041 100 Hour Inspection.................................................................1041 250 Hour Inspection.................................................................1041 500 Hour Inspection.................................................................1042 1000 Hour Inspection................................................................1042 PUMP REBUILD............................................................................1043 Disassembly.........................................................................1043 Cleaning and Inspection.............................................................1044 Assembly............................................................................1046 VENT VALVE REB UILD.....................................................................1047 Disassembly and Assembly............................................................1047 SYSTEM TROUBLESHOOTING CHART............................................................1048 SECTION P4 - MOTORIZED WHEEL MAINTENANCE SCHEDULE - INDEX.......................................1051 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................1053 AXLE BOX................................................................................1053 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................1054 ARMATURE AREA...........................................................................1054 AT TIRE CHANGE..........................................................................1054 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................1055 GENERATOR/ALTERNATOR....................................................................1055 GRID BLOWER MOTOR.......................................................................1055 CONTROL EQUIPMENT CHECKS................................................................1055 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................1056 VEHICLE OPERATIONS TESTS................................................................1056 SECTION R - SYSTEM SCHEMATICS - INDEX...............................................................1057 HYDRAULIC BRAKE SYSTEM SCHEMATIC - EF5755.......................................................1059 HYDRAULIC SYSTEM SCHEMATIC - EJ2729.............................................................1060 ELECTRICAL SCHEMATIC - XS0100...................................................................1061 VHMS SYSTEM SCHEMATIC - EL8720..................................................................1094
KOMATSU 730E DUMP TRUCK SHOP MANUAL A30427-A30538 – PDF DOWNLOAD:
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