Komatsu 730E Dump Truck Shop Manual CEBM020301 PDF

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Komatsu 730E Dump Truck Shop Manual CEBM020301 – PDF DOWNLOAD

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Komatsu 730E Dump Truck Shop Manual CEBM020301 – PDF DOWNLOAD 

Language : English
Pages : 1042
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 730E Dump Truck Shop Manual CEBM020301 – PDF DOWNLOAD

SERIAL NUMBERS A30539 – A30551

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
MAJOR COMPONENT DESCRIPTION 11
SPECIFICATIONS 13
Komatsu SSA16V159 13
SECTION A3 GENERAL SAFETY AND OPERATION INDEX 15
GENERAL SAFETY AND OPERATION 18
PERSONAL SAFETY 18
Safety Rules 18
Truck Safety Features 18
Clothing And Personal Items 18
Unauthorized Modification 18
Leaving The Operator’s Seat 18
Mounting And Dismounting 19
Fire Extinguishers And First Aid Kits 19
Precautions For High Temperature Fluids 19
Asbestos Dust Hazard Prevention 20
Fire Prevention For Fuel And Oil 20
ROPS Precautions 20
Preventing Injury From Work Equipment 20
Precautions For Optional Attachments 20
Precautions When Starting The Machine 21
PRECAUTIONS FOR TRUCK OPERATION 21
Safety Is Thinking Ahead 21
Safety At The Work Site 21
Fire Prevention 21
Preparing For Operation 21
Ventilation For Enclosed Areas 21
Mirrors, Windows, And Lights 22
In The Operator’s Cab – Before Starting The Engine 22
Seat Belts 22
OPERATING THE MACHINE 22
Starting The Engine 22
Truck Operation – General 23
Traveling In The Truck 23
Precautions When Traveling In Reverse 23
Traveling On Slopes 24
Ensuring Good Visibility 24
Operating On Snow 24
Avoid Damage To The Dump Body 24
Driving Near High-Voltage Cables 24
When Loading The Truck 24
When Dumping 24
Working On Loose Ground 25
Parking The Machine 25
TOWING 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump-Starting With Booster Cables 26
Jump Starting With Receptacles 26
PRECAUTIONS FOR MAINTENANCE 27
BEFORE PERFORMING MAINTENANCE 27
Stopping The Engine Before Service 27
Warning Tag 27
Proper Tools 27
Securing The Dump Body 27
DURING MAINTENANCE 28
Personnel 28
Attachments 28
Working Under The Machine 28
Keeping The Machine Clean 28
Rules To Follow When Adding Fuel Or Oil 28
Radiator Coolant Level 28
Use Of Lighting 28
Precautions With The Battery 29
Handling High-Pressure Hoses 29
Precautions With High-Pressure Oil 29
Maintenance Near High Temperatures And High Pressures 29
Rotating Fan And Belts 29
Waste Materials 29
TIRES 30
Handling Tires 30
Tire Maintenance 31
Storing Tires After Removal 31
ADDITIONAL JOB SITE RULES 32
WHEN REPAIRS ARE NECESSARY 33
OPERATING INSTRUCTIONS 34
PREPARING FOR OPERATION 34
SAFETY IS THINKING AHEAD 34
WALK AROUND INSPECTION 34
ENGINE START-UP 38
AFTER ENGINE HAS STARTED 39
EMERGENCY STEERING SYSTEM 40
Operation 40
Pre-Operation Testing 40
Additional Guidelines 41
MACHINE OPERATION SAFETY PRECAUTIONS 41
LOADING 42
HAULING 42
PASSING 43
DUMPING 43
To Raise The Dump Body: 43
To Lower The Dump Body: (When dumping over a berm or into a crusher): 44
To Lower The Dump Body (When dumping on flat ground): 44
TOWING 45
Towing Procedure 45
SAFE PARKING PROCEDURES 46
ENGINE SHUTDOWN PROCEDURE 46
DELAYED ENGINE SHUTDOWN PROCEDURE 46
SUDDEN LOSS OF POWER 47
WARNINGS AND CAUTIONS 49
SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX 67
STORAGE AND IDLE MACHINE PREPARATION 69
SHORT TERM IDLE PERIODS 69
PREPARATION FOR STORAGE 70
REMOVAL FROM STORAGE 71
RECONDITIONING AN IDLE VEHICLE 72
ENGINE OPERATION 75
After The Engine Has Started 75
ENGINE STORAGE 76
Temporary Storage (30 Days Or Less) 76
Extended Storage (More Than 30 Days) 77
RESTORING AN ENGINE AFTER EXTENDED STORAGE 78
ELECTRIC DRIVE TRUCKS 79
Storing A Truck That Is Operational 79
Storing A Truck That Is Not Operational 80
Storing A Major Component 81
Periodic Inspections 81
Placing Equipment Into Service After Storage 81
SECTION B STRUCTURES INDEX 83
SECTION B2 STRUCTURAL COMPONENTS INDEX 85
STRUCTURAL COMPONENTS 87
LADDERS 87
Removal 87
Installation 87
GRILLE AND HOOD 88
Removal 88
Installation 88
RIGHT-HAND DECK 88
Removal 88
Installation 90
CENTER DECK 90
LEFT-HAND DECK 91
Removal 91
Installation 91
SECTION B3 DUMP BODY INDEX 93
DUMP BODY 95
DUMP BODY 95
Removal 95
Installation 96
BODY SLING 96
BODY PADS 97
Adjustment 97
BODY GUIDE 98
BODY POSITION INDICATOR 98
HOIST LIMIT SWITCH 98
ROCK EJECTORS 98
Inspection 98
SECTION B4 FUEL TANK INDEX 99
FUEL TANK 101
Removal 101
Repair 101
Cleaning 101
Installation 102
FUEL GAUGE SENDER 103
Removal 103
Installation 103
LOW FUEL SENDER 104
Removal 104
Installation 104
TANK BREATHER VALVE 105
Removal 105
Installation 105
Disassembly 105
Assembly 105
FUEL RECEIVER (WIGGINS QUICK FILL) 106
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL) 107
SECTION C ENGINE INDEX 109
SECTION C2 POWER MODULE INDEX 111
POWER MODULE 113
GENERAL INFORMATION 113
POWER MODULE SERVICE 114
Removal 114
Installation 118
SECTION C3 COOLING SYSTEM INDEX 121
COOLING SYSTEM 123
RADIATOR 123
Removal 123
Service 124
Installation 124
RADIATOR FILL PROCEDURE 125
RADIATOR REPAIR 125
Internal Inspection 125
External Cleaning 126
Disassembly 126
Cleaning and Inspection 127
Assembly 127
Additional Service Information 129
PRESSURE TESTING 129
COOLANT SYSTEM TROUBLESHOOTING 129
SECTION C4 POWER TRAIN INDEX 131
POWER TRAIN 133
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 133
General Information 133
Removal 133
ALTERNATOR INSTALLATION 135
Engine/Alternator Mating 135
Alternator Measurement 135
Engine End Play Measurement 136
Determining Shim Requirements 137
Installing Alternator On Engine 138
ENGINE 139
Removal 139
Installation 139
SECTION C5 AIR CLEANERS INDEX 141
AIR CLEANERS 143
Service Checks 143
Filter Element Replacement 144
Main Filter Element Cleaning 146
Precleaner Section 147
Cleaning Precleaner Tubes 147
Air Intake Troubleshooting 148
SECTION C7 FAN DRIVE CLUTCH INDEX 149
FAN DRIVE CLUTCH 151
COMPONENTS 151
Input 151
Output 151
Stationary Components 152
OPERATIONAL MODES 153
Fully Engaged 153
Modulated Variable Speed 153
Fully Released 154
Lubricating and Cooling Oil 155
MAINTENANCE 156
TROUBLESHOOTING 157
Preliminary Checks 157
FIELD CHECK DIAGNOSIS 158
Preliminary Checks – Engine Off 158
Check Clutch Release 158
Check Clutch Lock-up 159
Overheating 159
Thermal Sensor and Solenoid Valve 160
On Truck Test 160
Off Truck Test 160
TROUBLESHOOTING CHART 162
FAN CLUTCH DISASSEMBLY INSTRUCTIONS 165
REASSEMBLY OF THE FAN CLUTCH 172
INSPECTION OF PARTS 183
REBUILD TOOLS 187
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 189
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 191
24VDC ELECTRIC SUPPLY SYSTEM 193
ELECTRICAL SYSTEM DESCRIPTION 193
BATTERIES 193
Maintenance and Service 193
Troubleshooting 193
BATTERY CHARGING ALTERNATOR 195
24VDC ELECTRIC START SYSTEM 195
CRANKING MOTORS 195
Removal 195
Installation 196
CRANKING MOTOR TROUBLESHOOTING 196
Preliminary Inspection 197
No-Load Test 197
Interpreting Results of Tests 197
Disassembly 198
Cleaning and Inspection 198
Armature Servicing 199
Field Coil Checks 201
Field Coil Removal 201
Solenoid Checks 201
Test 201
Assembly 203
Pinion Clearance 204
MAGNETIC SWITCH 204
Coil Test 204
Electric Start System Wiring Diagrams 204
ENGINE PRELUB SYSTEM 205
OPERATION 205
Pressure Switch 205
Suction Line 205
Outlet Line 205
Check Valve 205
Solenoid Timer 205
TROUBLESHOOTING PRELUB STARTER CIRCUIT 207
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 211
24VDC ELECTRICAL SYSTEM COMPONENTS 213
PASSENGER SEAT BASE COMPARTMENT 213
COMPONENTS 213
Taillight Resistor Diode Assemblies 213
Inclinometer 213
Brake Warning Buzzer (BWB) 213
Lubrication System Timer 213
Three Minute Idle Timer Components 213
Three Minute Idle Timer 215
Idle Timer Relay 215
Three Minute Idle Contactor 215
Three Minute Idle Circuit Test 215
Data Store Button 215
Komatsu Engine Quantum Connector (Not Used) 215
Komatsu Engine Cense Connector 215
STATEX III Propulsion System Diagnostic Connector 215
Modular Mining Port (Optional) 215
Alarm Indicating Device (AID) System 216
Diode Matrix (Without Sound) 216
Diode Matrix (With Sound) 217
Hot Switch Inverter 217
Hot Switch Inverter Card (Slot 4) (Not Used) 217
Temperature 217
Oil Level 217
Temperature and Latch 217
Coolant Level/Flasher 218
Lamp Test 218
BATTERY EQUALIZER BOX 218
Troubleshooting 218
BODY-UP SWITCH 219
Adjustment 219
Service 219
HOIST LIMIT SWITCH 220
Adjustment 220
Service 220
24-VOLT RELAY AND DIODE BOARDS 220
RELAY BOARDS 221
Description 221
SERVICE 221
To Replace A Relay: 221
To Replace A Circuit Breaker: 221
To Replace A Circuit Panel Card 222
Relay Board Components 222
Installing Additional Circuits 223
DIODE BOARD 1 224
Diode Testing 224
CIRCUIT BREAKERS 226
SECTION D10 CHARGING SYSTEM INDEX 227
CHARGING SYSTEM 229
CHARGING SYSTEM DESCRIPTION 229
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION 229
Excessive heat 229
Dirt and dust 229
Vibration 229
PREVENTIVE MAINTENANCE PROCEDURES 230
Alternator Cleanliness 230
Alternator Mounting 230
Belt Tension And Condition 230
TROUBLESHOOTING PROCEDURES 230
ALTERNATOR PERFORMANCE TEST 230
ALTERNATOR CABLE TEST 231
VOLTAGE REGULATOR ADJUSTMENT 232
ALTERNATOR 233
Removal 233
Installation 234
SECTION D11 VHMS COMPONENTS INDEX 237
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 239
VHMS BASIC FEATURES 239
Gather Data 239
Convert and Record Data 240
Communicate Data to Off-Board Systems 240
USING THE VHMS SYSTEM 241
Basic Precautions 241
Turning the VHMS System On 241
Normal VHMS Operation 242
Turning the VHMS System Off 242
Downloading From the VHMS Controller 242
VHMS DATA ITEMS 243
Fault Codes 243
Machine History 243
VHMS History 244
Snapshots 244
Manual Snapshots 244
Trends 244
Histogram (Load Map) Data 246
Haul Cycle Data 247
Alarm and Snapshot Triggers 248
Satellite Features 250
VHMS DIAGNOSTIC FEATURES 250
Fault History 250
VHMS LED Digits 250
Light (10) PLM III communication 250
Light (11) OrbComm 250
VHMS COMPONENTS 251
VHMS CONTROLLER 251
Removal 252
Installation 252
OrbComm Controller 253
Removal 253
Installation 254
INTERFACE MODULE 254
Inputs 255
Outputs 255
Removal 255
Installation 255
COMPONENT LOCATION 256
Circuit Breakers 256
Temperature Sensors 257
Pressure Sensors 258
VHMS SOFTWARE 261
Necessary Software 261
Necessary Tools 262
VHMS TOOL BOX INSTALLATION 262
VHMS SETTING TOOL INSTALLATION 263
VHMS INITIALIZATION PROCEDURE 263
Preliminary Checks 263
Initialization Steps 263
Select Operation 264
VHMS Setting Function 264
Machine Information Setting(1) 264
Machine Information Setting(2) 264
Date and Time Setting 265
GCC Setting 265
Setting Summary 265
VHMS SNAPSHOT PROCEDURE 266
VHMS DOWNLOAD 266
VHMS FTP UPLOAD 267
LOCATION OF DOWNLOAD FILES 268
INSTALLING FLASHBURN PROGRAM 269
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 269
INSTALLING REALTIME MONITOR SOFTWARE PROGRAM 270
WHEN REPLACING A VHMS CONTROLLER 270
To Set: Date and time, satellite, payload meter 272
Review Setting Information 274
SECTION D12 VHMS SOFTWARE INDEX 259
SECTION D13 VHMS CHECKOUT AND TROUBLESHOOTING INDEX 275
VHMS CHECKOUT AND TROUBLESHOOTING 277
VHMS CHECKOUT PROCEDURE 277
General 277
Structure and Purpose 278
Necessary Equipment: 278
VHMS SYSTEM CHECKOUT 278
Preliminary 278
Checking Inputs To The Interface Module 279
For 930E & 960E trucks only: 281
For 830E trucks only: 281
Checking Outputs From The Interface Module 282
For 830E only: 282
For 930E & 960E only: 282
VHMS CONTROLLER CHECKOUT 282
TROUBLESHOOTING 283
Communications Networks 283
Coaxial Cable 283
VHMS COMPONENTS 284
VHMS Controller 284
OrbComm Controller 285
Interface Module 285
FAULT CODES 286
Fault History 286
VHMS LED Display Fault Codes 287
Chassis Fault Codes 288
Engine Fault Codes 292
FAULT TREE ANALYSIS 298
Unable to connect to VHMS from laptop PC 298
Flashing Error Code N4-23 (PLM III Communications Fault) 299
Flashing Error Code N4-22 (Engine Communications Fault) 300
No Data Received By WebCARE 301
Coaxial Cable Troubleshooting 302
SECTION D14 VHMS FORMS INDEX 303
VHMS FORMS 305
VHMS INITIALIZATION CHECK LIST 305
VHMS DATA DOWNLOAD 306
VHMS INITIALIZATION FORM 306
VHMS INITIALIZATION CHECK LIST 308
VHMS INITIALIZATION FORM 310
SECTION D35 PAYLOAD METER III INDEX 311
OPERATION SECTION 315
Introduction 315
Data Summary 315
Data Gathering 315
COMPONENT DESCRIPTION 316
System Diagram 316
Suspension Pressure Sensors 316
Inclinometer 316
Operator Display 316
Operator Switch 317
Speed Input 317
Body-Up Switch 317
Brake Lock Switch 317
Payload Meter 317
Communications Ports 317
Key Switch Input 318
Payload Meter Power 318
Load Lights 318
Wiring and Termination 319
TCI Outputs 319
OPERATOR’S DISPLAY AND SWITCH 320
Reading the Speedometer 320
Reading the Load Display 320
Using the Operator ID 320
Using the Load and Ton Counter 320
Total Ton Counter 320
Total Load Counter 321
Clearing the Counters 321
Viewing Live Sensor Data 321
Other Display Messages 321
PAYLOAD OPERATION & CALCULATION 322
Description of Haul Cycle States 322
Haul Cycle Description 322
Load Calculation 323
Carry Back 323
Measurement Accuracy 323
SOURCES FOR PAYLOAD ERROR 323
Payload Error 323
Loading Conditions 324
Pressure Sensors 324
Swingloads 324
Speed and Distance 324
HAUL CYCLE DATA 324
Haul Cycle Warning Flags 326
Frame Torque Data 327
Sprung Weight Data 327
Maximum Speed Data 327
Alarm Records 327
Fault Code Data 328
PC SOFTWARE OVERVIEW 329
System Configuration 329
Installing the PLMIII Software 329
DOWNLOADING DATA 330
PLM III SYSTEM CONFIGURATION 331
Starting Communications 331
Displayed Payload Units 331
Time Units 331
Connection Menu 331
Connecting to the Payload Meter 332
Configure the Payload Meter 332
Setting the Date and Time 332
Setting the Truck Type 333
Setting the Gauge Display Units 333
Setting the Frame Serial Number 333
Setting the Truck Number 333
Setting the Komatsu Distributor 333
Setting the Komatsu Customer 333
Clean Truck Tare 334
Inclinometer Calibration 334
DATA ANALYSIS 335
Creating a Query 335
Sorting on Truck Unit Number 335
Sorting on Truck Type 335
Sorting on Date Range 336
Sorting on Time Range 336
Payload Detail Screen 337
Creating Reports 337
Summary – one page report 338
Detailed – multi-page report 338
Creating Graphs 339
Exporting Data 339
CSV Export 339
Compressed 340
Importing Data 341
Deleting Haul Cycle Records 341
Viewing Alarms 342
Deleting Alarm Records 342
TROUBLESHOOTING SECTION 343
TROUBLESHOOTING 343
Viewing Active Alarms 343
Real-Time Data Display 343
Testing the Payload Lights 343
Creating Log Files of Inputs 344
Daily Inspections 344
Periodic Maintenance 344
Abnormal Displays at Power-Up 345
No Payload Display When Key Switch is Turned ON 346
No Display on Speedometer 347
No Display on Operator Display 347
No Communications With PC 348
Load Lights Don’t Light During Loading 349
Load Lights Remain ON 350
Load Lights Remain ON During Dumping 350
Display Doesn’t Clear When The Load Is Dumped 350
Calibration Problems 351
Alarm 1 – Left Front Pressure High 352
Alarm 2 – Left Front Pressure Low 352
Troubleshoot Wiring to Left Front Suspension 352
Alarm 3 – Right Front Pressure High 353
Alarm 4 – Right Front Pressure Low 353
Troubleshoot Wiring to Right Front Suspension 353
Alarm 5 -Left Rear Pressure High 354
Alarm 6 – Left Rear Pressure Low 354
Troubleshoot Wiring to Left Rear Suspension 354
Alarm 7 – Right Rear Pressure High 355
Alarm 8 – Right Rear Pressure Low 355
Troubleshoot Wiring to Right Rear Suspension 355
Alarm 9 – Inclinometer High 356
Alarm 10 – Inclinometer Low 356
Troubleshoot Inclinometer Wiring 356
Alarm 13 – Body Up Input Failure 357
Alarm 16 – Memory Write Failure 358
Alarm 17 – Memory Read Failure 358
Alarm 18 359
Alarm 19 359
Alarm 22 359
Operator Switch Doesn’t Work 360
Alarm 26 – User Switch Fault – SELECT 360
Alarm 27 – User Switch Fault – SET 360
Connector Map 361
Connectors 362
PLMIII CHECK OUT PROCEDURE 363
General Description 363
Tools Required 363
Checkout Procedure 363
PLMIII CHECKOUT PROCEDURE CONFIRMATION 367
Flashburn Programming 367
Confirmation Checklist 369
SECTION E ELECTRICAL PROPULSION INDEX 371
SECTION E2 ELECTRICAL PROPULSION COMPONENTS INDEX 373
ELECTRICAL PROPULSION COMPONENTS 377
GENERAL SYSTEM DESCRIPTION 377
CONTROL SYSTEM 377
System Operation 378
FL275 Panel 379
CARD REPLACEMENT 380
Removal 380
Installation 380
Card Repair 380
Panel Wiring 380
COMPUTER DESCRIPTION 381
Microprocessor 381
Download Capability 381
SOFTWARE 381
Base Monitor Program 381
Runtime Monitor Program – OBJ Running Code 381
Configuration Software – CFG 382
PTU – Portable Test Unit Code 382
System Regulation 382
Propulsion 383
Retarding 383
TWO-DIGIT DISPLAY PANEL 384
The Coded Number 384
Events 384
Frames 385
Windows 385
System Categories 385
Limits On Resetting Faults 385
NA Faults 386
Event Sequence 386
Resetting Events 386
Event Descriptions 386
Subcode Descriptions 386
2-DIGIT DISPLAY PANEL SUBCODES 394
PORTABLE TEST UNIT (PTU) 397
DESCRIPTION 397
Operational Hints 397
SOFTWARE INSTALLATION PREPARATION 398
HARD DISK SPACE REQUIREMENTS 398
SOFTWARE INSTALLATION ON PTU 398
PTU/Truck Communication Problems 399
THE MAIN MENU 400
Quit Menu 400
PTU Talk To Truck 400
View PTU Saved Files 400
List Stat Data Files 400
Truck Setup (CFG) 400
Select Truck Setup 400
Update CFG Version 400
Change PTU Password 400
CONFIGURATION (CFG) FILE CONVERSION 402
Conversion Procedure 402
Convert Old CFG files for New software 403
STATEX CONFIGURATION FILES 406
0) Source Directory: 406
1) Select A Truck Configuration 407
2) View Truck Configuration: Data Curves 408
3) Change/View Serial and Model Numbers 409
4) View Options 409
5) Change/View Truck Specifics 411
6) Change/View Overspeeds 413
7) Save a Truck Configuration, filename: 414
8) Save Directory: 415
CHANGE PTU PASSWORD 416
PROGRAMMING THE TRUCK 417
Connect PTU to the Truck 417
Select Configuration File 417
Activate The PTU Mode 417
Check Object Code Version 418
Download Configuration Files 419
Date And Time 420
Event Data 421
Statistical Data 423
View Counters 423
View Profiles 423
Upload Statistical Data To A File 423
Statistical Data Codes – Counters 424
STATISTICAL DATA CODES – COUNTERS 425
STATISTICAL DATA CODES – PROFILES 430
TRUCK SPECIFIC INFORMATION 434
Temporary Truck Settings 435
MISCELLANEOUS FEATURES 436
Saving Data 436
PTU Abbreviations 437
Other Menu Selections 437
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 438
ALTERNATOR 438
ELECTRIC WHEEL MOTORS 438
RETARDING GRIDS 438
ELECTRONIC ACCELERATOR AND RETARD PEDALS 438
Removal 438
Installation 438
Disassembly 439
Reassembly 439
COOLING BLOWER WARNING SYSTEM 439
Operation 439
Test 439
Removal 440
Installation 440
ELECTRICAL CONTROL CABINET 441
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 446
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 447
SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX 449
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 453
GENERAL INFORMATION 453
COMMUNICATIONS PORT CHECK 454
PTU Hookup 454
4 0 SEQUENCE TESTS – (ENGINE NOT ON) 455
Preparation and Setup 455
CONTROL SYSTEM SELF-TEST 456
4 1 THROTTLE SYSTEM CHECK AND ADJUSTMENT 456
4 2 RETARD SYSTEM CHECK AND ADJUSTMENT 457
PTU Setup 457
4 3 REVERSER AND PROPULSION CONTACTORS CHECK 458
4 4 NOT USED 459
4 5 RETARD CONTACTORS OPERATION CHECK 459
4 6 GROUND FAULT SENSING CHECK 459
4 7 GROUND FAULT IN RETARD OPERATION CHECK 460
4 8 OVERRIDE OPERATION CHECK 460
4 9 ANTI-REVERSAL FUNCTION (AR) CHECK 461
4 10 OVERSPEED RETARD OPERATION CHECK 461
4 11 HOIST INTERLOCK OPERATION CHECK 462
4 12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK 462
Return to Main Menu 462
5 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 463
5 1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU 463
5 2 DIGITAL INPUT CHECKS 464
5 3 DIGITAL OUTPUT CHECKS 465
6 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 469
6 1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU 469
6 2 ANALOG INPUT CHECKS 470
6 3 FREQUENCY INPUT CHECKS 474
Return to Main Menu 475
7 0 SPEED EVENT CHECKS 475
Preparation and Setup 475
Setup PTU 475
7 1 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK 476
7 2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK 476
7 3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK 476
7 4 OTHER SPEED EVENTS CHECKS 476
Return to Main Menu 476
8 0 RETARD SPEED CONTROL SYSTEM CHECK 477
Preparation and Setup 477
Setup PTU 477
8 1 OVERSPEED PICKUP AND DROPOUT CHECK 477
8 2 RETARD POT MAXIMUM SETTING CHECK 477
8 3 RETARD POT MINIMUM SETTING CHECK 477
8 4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL 478
Return to Main Menu 478
9 0 LOAD TEST USING TRUCK RETARD GRIDS 478
Setup and Preparation 478
PTU Setup 478
9 1 LOAD TEST 479
10 0 MOTOR FIELD CURRENT CHECK IN RETARDING 479
Setup PTU 479
10 1 RETARD CHECK 480
11 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 481
11 1 BRAKE SYSTEM INTERLOCKS CHECK 481
Preparation 481
11 2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT 481
11 3 SYNC TRANSFORMER CHECKOUT 482
11 4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT 482
11 5 BATTERY BOOST ADJUSTMENT 482
11 6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST 482
11 7 MOTOR ROTATION TEST 483
11 8 GROUND FAULT CHECKS 483
12 0 MISCELLANEOUS CHARTS 484
12 1 WHEEL MOTOR GEAR RATIOS 484
12 2 MAXIMUM ALLOWABLE TRUCK SPEEDS 485
12 3 ENGINE OPTIONS 486
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX 487
SECTION G2 TIRES AND RIMS INDEX 489
TIRES AND RIMS 491
GENERAL INFORMATION 491
TIRES 491
Handling Tires 491
Tire Maintenance 492
Storing Tires After Removal 492
FRONT TIRES AND RIMS 493
Removal 493
Installation 494
REAR TIRES AND RIMS 495
Removal 495
Installation 496
RIM 497
Tire Removal 497
RIM AND TIRE PREPARATION 498
LUBRICANTS 498
TIRE INSTALLATION 499
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 501
FRONT WHEEL HUB AND SPINDLE 503
WHEEL HUB AND SPINDLE ASSEMBLY 503
Removal 503
Installation 505
Disassembly 506
Cleaning and Inspection 507
Assembly 507
Wheel Bearing Adjustment (Spindle Vertical) 510
Wheel Bearing Adjustment (Tire Mounted) 511
STEERING CYLINDERS AND TIE ROD 515
Spherical Bearing Wear Limits 515
Removal 516
Installation 518
Bearing Replacement 518
TOE-IN ADJUSTMENT 519
SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX 521
REAR AXLE HOUSING 523
PIVOT PIN 523
Removal 523
Installation 524
PIVOT EYE BEARING 524
Disassembly 524
Assembly 525
PIVOT EYE REPAIR 525
Removal 525
Disassembly 525
Bushing (New) 525
Pivot Eye Bore (New) 525
Assembly 525
Installation 526
ANTI-SWAY BAR 526
Removal 526
Installation 526
Disassembly 527
Cleaning and Inspection 527
Assembly 527
SECTION G5 REAR AXLE HOUSING INDEX 529
REAR AXLE HOUSING 531
REAR AXLE HOUSING 531
Removal 531
Installation 531
WHEEL MOTOR 531
Removal 531
Cleaning and Inspection 532
Installation 532
Maximum Cap Screw Usage 532
SECTION H SUSPENSIONS INDEX 533
SECTION H2 FRONT SUSPENSION INDEX 535
FRONT SUSPENSION 537
Removal 537
Installation 539
Turn-of-the-Nut Tightening Procedure 540
Disassembly 541
Cleaning and Inspection 542
Assembly (Bearing Only) 542
Suspension Assembly (Complete) 542
SUSPENSION PRESSURE TEST 544
SECTION H3 REAR SUSPENSIONS INDEX 547
REAR SUSPENSIONS 549
Removal 550
Installation 552
Disassembly 552
Cleaning and Inspection 552
Assembly 553
SUSPENSION PRESSURE TEST 555
SECTION H4 OILING AND CHARGING PROCEDURES INDEX 557
OILING AND CHARGING PROCEDURE 559
GENERAL 559
EQUIPMENT LIST 559
Hydrair® Charging Kit 559
Installation of Charging Kit 559
Removal of Charging Kit 560
Support Blocks For Oiling and Charging Dimensions 560
FRONT SUSPENSION 561
Front Suspension Oiling 561
Front Suspension Nitrogen Charging 562
REAR SUSPENSION 564
Rear Suspension Oiling 564
Rear Suspension Nitrogen Charging 566
OIL AND NITROGEN SPECIFICATIONS CHART 567
SECTION J BRAKE CIRCUIT INDEX 569
SECTION J2 BRAKE CIRCUIT INDEX 571
BRAKE CIRCUIT 573
GENERAL DESCRIPTION 573
SERVICE BRAKE CIRCUIT 573
SECONDARY BRAKING AND AUTOMATIC APPLY 575
PARKING BRAKE CIRCUIT 575
Normal Operation (key switch on, engine on) 575
BRAKE LOCK CIRCUIT 576
WARNING CIRCUIT 576
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 579
BRAKE CIRCUIT COMPONENT SERVICE 581
BRAKE VALVE 581
Rebuild Criteria 581
Removal 581
Installation 583
Disassembly 585
Cleaning and Inspection 587
ASSEMBLY 587
Actuator Base Threaded Inserts 587
Boot and Cap 587
Valve Body Seal Installation 588
Regulator Sleeve O-Ring Installation 589
Actuator Plunger O-Ring Installation 589
Assembly of Valve 589
DIFFERENTIAL PRESSURE SWITCH 590
Disassembly 591
Cleaning and Inspection 591
Assembly 591
VALVE BENCH TEST AND ADJUSTMENT 591
Test Set Up Procedure 593
Brake Valve Output Pressure Adjustment 593
Differential Pressure Switch Test 594
Final Test and Adjustment 594
Installation Of Brake Pedal Actuator Assembly to Brake Valve 595
HYDRAULIC BRAKE ACCUMULATORS 597
Brake Accumulator Bleed-Down Procedure 597
Removal 597
Installation 599
Disassembly 599
Cleaning and Inspection 601
Assembly 601
Leak Testing 604
BRAKE ACCUMULATOR CHARGING 605
Temperature During Precharge 607
ACCUMULATOR STORAGE 607
Installation 608
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 609
BRAKE CIRCUIT CHECK-OUT PROCEDURE 611
EQUIPMENT REQUIRED 614
INITIAL SYSTEM SET-UP 615
Parking Brake 615
Service Brakes 616
Brake Lock/Secondary 616
Low Brake Pressure and Auto Apply 617
Reapplications 617
Differential Pressure Switch 617
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 619
The Brakes are Locked, Service, and/or Parking 619
Both Brake Circuits are Dragging 619
One Brake Circuit is Dragging 619
Brakes are Not Going to Full Pressure 619
A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off 619
Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released 620
Differential Pressure Warning Circuit is Not Operating 620
A Low Brake Pressure Warning Occurs When Brakes are Applied 620
Low Pressure Warning Circuit Not Operating Properly 620
Low Pressure Warning is On Even Though System Pressure is Correct 621
Low Pressure Warning Comes On and Pressure is Low 621
A Squeal is Heard When Controller is Operated 621
Output Pressure At Controller is Correct but Brakes are Not Applying 621
Brake Pressures Drift Excessively While Pedal is Held Steady 621
Oil is Leaking Around the Pedal Base 621
Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM 621
CHECK-OUT PROCEDURE 622
HYDRAULIC BRAKE SYSTEM DATA SHEET 622
SECTION J5 FRONT DISC BRAKES INDEX 625
FRONT DISC BRAKES 627
BRAKE CALIPER 627
Removal 627
Installation 628
Disassembly 629
Cleaning and Inspection 629
Assembly 631
BRAKE LINING 631
Replacement 631
FRONT SERVICE BRAKE BURNISHING 633
BRAKE BLEEDING PROCEDURE 634
SECTION J6 REAR BRAKES INDEX 635
REAR DISC BRAKES 637
REAR BRAKES 637
CALIPER, DISC, AND PARKING BRAKE 637
Removal 637
Installation 638
CALIPER PISTON 640
Piston Assembly Removal 640
Inspection 640
Piston Assembly Installation 641
FUNCTIONAL TEST OF PISTON ASSEMBLY 642
Return Spring Force 642
Built-In Clearance 642
Grip Force 644
Grip Force Measurement 645
Spring Force Measurement 647
Disassembly of Piston Assembly 648
Assembly of Piston Assembly 649
BENCH TEST 649
BRAKE LINING 650
Replacement 650
SERVICE BRAKE BURNISHING 653
SAFETY PRECAUTIONS 653
Rear Brake Burnishing 654
BRAKE BLEEDING PROCEDURE 655
Spring Force Measurement 656
SECTION J7 PARKING BRAKE INDEX 657
PARKING BRAKE 659
GENERAL INFORMATION 659
PARKING BRAKE CALIPER 659
Lining Thickness Inspection 659
Removal 660
Installation 660
Parking Brake Adjustment 661
Parking Brake Caliper Disassembly 662
Cleaning and Inspection 663
Parking Brake Caliper Assembly 664
PARKING BRAKE LINING REPLACEMENT 664
PARKING BRAKE BURNISH PROCEDURE 664
Lining Conditioning 664
BRAKE BLEEDING PROCEDURE 665
SECTION L HYDRAULIC SYSTEM INDEX 667
SECTION L2 HYDRAULIC SYSTEM INDEX 669
HYDRAULIC SYSTEM 671
GENERAL INFORMATION 671
HYDRAULIC SYSTEMS OPERATION 671
Hoist Circuit Operation 671
Steering Circuit Operation 673
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 677
HYDRAULIC SYSTEM COMPONENT REPAIR 679
HOIST PUMP 679
Removal 679
Installation 680
Disassembly 681
Inspection of Parts 684
Assembly 684
Troubleshooting Guide 688
HYDRAULIC TANK 689
Filling Instructions 689
Removal 690
Installation 690
HYDRAULIC TANK STRAINER AND DIFFUSER 690
Removal 690
Inspect and Clean 691
Installation 691
SECTION L4 STEERING CIRCUIT INDEX 693
STEERING CIRCUIT 695
STEERING CIRCUIT OPERATION 695
COMPONENT DESCRIPTION 696
Steering Control Valve 696
Unloader Valve 697
Bleed-Down Manifold Valve 697
Flow Amplifier 703
FLOW AMPLIFIER SYSTEM OPERATION 704
No Steer 704
Steering Left 706
Steering Right 708
No Steer, External Shock Load 710
Steering Pump 712
High Pressure Filter 712
Accumulators 712
Low Precharge Warning Switch 712
SECTION L5 STEERING CONTROL UNIT INDEX 713
STEERING CONTROL UNIT 715
GENERAL INFORMATION 715
Removal 715
Installation 715
STEERING CONTROL UNIT REBUILD 717
Disassembly 717
Cleaning and Inspection 718
Assembly 720
STEERING/BRAKE PUMP 723
Removal 723
Installation 723
Disassembly 725
Inspection of Parts 726
Assembly 726
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 729
STEERING CIRCUIT COMPONENT REPAIR 731
BLEED-DOWN MANIFOLD 731
Removal 731
Installation 731
ACCUMULATOR 732
Removal 732
Installation 733
Disassembly 734
Cleaning and Inspection 734
Assembly 735
Leak Testing 736
STEERING ACCUMULATOR CHARGING 737
Temperature During Precharge 740
ACCUMULATOR STORAGE 741
Installation 741
FLOW AMPLIFIER 742
Removal 742
Installation 742
Disassembly 743
Assembly 746
STEERING CYLINDERS 747
Disassembly 747
Piston Seal and Bearing Installation 747
Cylinder Assembly 747
Test 747
TROUBLESHOOTING CHART 750
SECTION L7 HOIST CIRCUIT INDEX 755
HOIST CIRCUIT 757
HOIST CIRCUIT OPERATION 757
COMPONENT DESCRIPTION 758
Hydraulic Tank 758
Hydraulic Pump 758
High Pressure Filter 758
Hoist Valve 758
Hoist Pilot Valve 759
Bleed-Down Manifold 760
Counterbalance Manifold 760
Hoist-Up Limit Solenoid 760
Pilot Operated Check Valve 760
HOIST VALVE OPERATION 762
Float Operation 762
Power Up Operation (Figure 7-6) 764
Hold Operation (Figure 7-7) 766
Power Down Operation (Figure 7-8) 768
Float Operation (Figure 7-9) 770
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 773
HOIST CIRCUIT COMPONENT REPAIR 775
HOIST VALVE 775
Removal 775
Installation 775
O-Ring Replacement 777
INLET SECTION 778
Disassembly 778
Cleaning and Inspection 779
Assembly 779
REAR SPOOL SECTION (WORK PORTS) 780
Disassembly 780
Cleaning and Inspection 782
Assembly 782
HOIST PILOT VALVE 784
Removal 784
Installation 784
Disassembly 785
Cleaning and Inspection 786
Assembly 786
HOIST UP LIMIT SOLENOID VALVE 787
HOIST CYLINDERS 787
Removal 787
Installation 788
Disassembly 791
Cleaning and Inspection 792
SS1143 Tightening Tool – Assembly Drawing 793
ASSEMBLY OF QUILL AND CYLINDER 793
Quill Installation 793
Installation Of Check Balls And Plugs In Quill 794
Assembly of Cylinder 796
COUNTERBALANCE MANIFOLD 797
SECTION L9 HIGH PRESSURE FILTERS INDEX 799
HYDRAULIC SYSTEM FILTERS 801
HOIST CIRCUIT FILTER 801
Filter Element Replacement 801
Removal 802
Installation 802
Indicator Switch 802
STEERING CIRCUIT FILTER 803
Filter Element Replacement 803
Removal 804
Installation 804
Indicator Switch 804
INDICATOR SWITCH 804
Test Procedure 804
SECTION L10 HYDRAULIC CHECK-OUT PROCEDURE INDEX 807
HYDRAULIC CHECK-OUT PROCEDURE 809
INITIAL START UP AND FLUSHING 809
COMPONENT CHECKOUT AND ADJUSTMENT 811
ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE 813
Counterbalance Valve Adjustment 815
Manifold Assembly 815
OIL CLEANLINESS CHECK 815
Oil Sampling Location On Truck 815
Oil Sampling Process and Cleanliness Criteria 816
DISABLED TRUCK DUMPING PROCEDURE 816
Hookup 816
Raising the Body 816
Lowering the Body 817
TROUBLESHOOTING CHART 818
Hoist Pump 818
Steering Circuit 820
Brake/Steering Pump 822
Flow Amplifier – Refer to Figure 10-9 824
SECTION M OPTIONS AND SPECIAL TOOLS 825
OPTIONS AND SPECIAL TOOLS INDEX 825
SECTION M7 HEATER OPTIONS INDEX 827
ENGINE OIL HEATERS 829
GENERAL INFORMATION 829
TROUBLESHOOTING 829
HEATER ELEMENT 829
Removal 829
Installation 830
ENGINE COOLANT HEATER 831
GENERAL 831
Maintenance 831
HEATING ELEMENT 831
Removal 831
Installation 832
THERMOSTAT 832
Removal 832
Installation 832
HYDRAULIC OIL HEATERS 833
GENERAL INFORMATION 833
TROUBLESHOOTING 833
HEATER ELEMENT 833
Removal 833
Installation 834
SECTION M8 SPECIAL TOOLS INDEX 835
SECTION N OPERATOR’S CAB INDEX 845
SECTION N2 TRUCK CAB INDEX 847
SECTION N3 CAB COMPONENTS INDEX 867
CAB COMPONENTS 869
WINDSHIELD WIPERS 869
WIPER MOTOR REPLACEMENT 869
Removal 869
Installation 869
WIPER ARM REPLACEMENT 869
Removal 869
Installation 870
WIPER LINKAGE REPLACEMENT 870
Removal 870
Installation 871
WINDSHIELD WASHER 871
Operation 871
Service 871
SECTION N4 OPERATOR COMFORT INDEX 873
HEATER/AIR CONDITIONER 877
CONTROLS 877
Operation 877
Heater/Air Conditioner Vents 877
Defroster Vent Control Switch 877
Heat Control Switch 877
Temperature Control Knob 877
Fan Control Knob 877
Heater/Air Conditioner Selector Switch 877
COMPONENTS 878
Circuit Breakers 878
Relays 878
Heater Core 878
Fan Motor and Speed Control 879
Test 879
Actuators 879
Test 879
Cab Air Filter 880
AIR CONDITIONING SYSTEM 882
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 883
PRINCIPLES OF REFRIGERATION 883
Air Conditioning 883
Refrigeration – The Act of Cooling 884
The Refrigeration Cycle 884
AIR CONDITIONER SYSTEM COMPONENTS 885
Compressor (Refrigerant Pump) 885
Service Valves 885
Receiver-Drier 885
Condenser 885
Expansion Block Valve 886
Accumulator 886
Evaporator 887
ELECTRICAL CIRCUIT 887
Thermostat 887
Compressor Clutch 888
Trinary™ Switch 888
SYSTEM SERVICING 890
SERVICE TOOLS AND EQUIPMENT 891
Recovery/Recycle Station 891
Leak Detector 892
Service Valves 892
Vacuum Pump 892
Manifold Gauge Set 893
Low Side Gauge 893
High Side Gauge 893
Installing Manifold Gauge Set 894
Purging Air From Service Hoses 894
SYSTEM PERFORMANCE TEST 895
SYSTEM OIL 896
Handling and Reusing RPAG Oil 896
Oil Quantity 896
Checking System Oil 896
REFRIGERANT 897
Recycled Refrigerant 897
Reclaimed Refrigerant 897
Refrigerant Quantity 898
R-134a Refrigerant Containers 898
SYSTEM LEAK TESTING 898
Electronic Leak Detector 899
Tracer Dyes 899
Soap and Water 899
RECOVERING AND RECYCLING THE REFRIGERANT 899
Performing the Recovery Cycle 899
Performing the Recycling Procedure 900
Evacuating and Charging the A/C System 900
SYSTEM REPAIR 900
System Flushing 901
COMPONENT REPLACEMENT 901
Hoses and Fittings 901
Lines 901
Expansion Valve 902
Receiver-Drier 902
Thermostat 902
Compressor 902
Accumulator 903
Clutch 903
Servicing the Compressor Clutch 904
Pulley Removal 906
Clutch Coil Check 906
Pulley Installation 907
Clutch Assembly Installation 907
EVACUATING THE SYSTEM 908
CHARGING THE A/C SYSTEM 910
AIR CONDITIONER DRIVE BELT 910
Pulley Alignment 910
Belt Tension 911
TROUBLESHOOTING 912
Preliminary Checks 912
Diagnosis of Gauge Readings and System Performance 913
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 914
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 920
SECTION N5 OPERATOR CONTROLS AND EQUIPMENT INDEX 921
OPERATOR CONTROLS 923
STEERING WHEEL AND CONTROLS 924
STEERING WHEEL 924
HORN BUTTON 924
TILT/TELESCOPE LEVER 924
M ULTI-FUNCTION TURN SIGNAL SWITCH 924
Turn Signal Operation 924
High Beam Headlight Operation 924
Windshield Wiper Operation 924
STEERING COLUMN 925
Removal 925
Inspection 925
Installation 926
PEDALS 926
SERVICE BRAKE PEDAL 926
DYNAMIC RETARDER PEDAL 926
Optional – Dual Function/Single Pedal 927
THROTTLE PEDAL 927
GRADE/SPEED WARNING CHART 927
OVERHEAD PANEL CONTROLS AND COMPONENTS 928
RADIO SPEAKERS 928
WARNING ALARM BUZZER 928
CAB RADIO 928
WARNING LIGHTS DIMMER CONTROL 928
WARNING/STATUS INDICATOR LIGHT PANEL 928
AIR CLEANER VACUUM GAUGES 928
WINDSHIELD WIPERS 928
TRUCK CONTROLS 929
F-N-R Selector Switch 929
Hoist Control Lever 930
CONSOLE SWITCHES AND CONTROLS 930
Ashtray 930
Cigarette Lighter 930
Left-Hand Window Control Switch 930
Right-Hand Window Control Switch 930
Engine Shutdown Switch 930
Override Switch 930
Retard Speed Control (RSC) Switch 931
Retard Speed Control (RSC) Dial 931
Statex III Download Port 932
Engine Diagnostic Port (CENSE) 932
Modular Mining Port 932
Passenger Seat 932
Engine Diagnostic Connectors 932
Engine Diagnostics Connector 932
Data Storage Button 932
PAYLOAD METER 932
Payload Meter Download Connector 932
OPERATOR SEAT 933
ADJUSTMENT 933
INSTRUMENT PANEL 934
CONTROL SYMBOLS 934
CONTROL SWITCHES AND GAUGES 935
Key Switch 935
Engine Shutdown Switch With Timer Delay 936
Fog Light Switch 936
Ladder Light Switch 936
Backup Light Switch 936
Panel Illumination Lights 936
Cab Air Conditioner/Heater Vents 936
Engine Cold Weather Starting Aid Switch 936
Rotating Beacon Light Switch 936
Heated Mirror Switch 936
Wheel Brake Lock Switch 937
Parking Brake Switch 937
Digital Tachometer 937
Right Turn Signal Indicator Light 938
High Beam Headlight Indicator Light 938
Left Turn Signal Indicator Light 938
Digital Speedometer/Payload Meter Display 938
Voltmeter Gauge 938
Engine Oil Pressure Gauge 938
Engine Water Temperature Gauge 938
Fuel Gauge 938
Engine Hourmeter 938
Headlight Switch 939
Panel Illumination Lights Dimmer Rheostat 939
Payload Meter Switch 939
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL 940
DESCRIPTION OF INDICATOR SYMBOLS 940
INDICATOR LIGHT FUNCTIONS 941
High Hydraulic Oil Temperature 941
Low Steering Pressure 941
Low Accumulator Precharge Pressure Warning 941
Electric System Fault Warning 942
Low Brake Pressure Indicator 942
Low Hydraulic Tank Level 942
Low Automatic Lubrication System Pressure 942
Circuit Breaker Tripped 942
Hydraulic Oil Filter 942
Low Fuel Indicator 943
Parking Brake Indicator 943
Service Brake Indicator 943
Body Up Indicator 943
Dynamic Retarding Indicator 943
Stop Engine Warning 943
Backup Indicator 943
Engine Shutdown Timer Switch 943
Retard Speed Control 943
Check Engine 944
Service Engine Indicator (AEM) 944
High Wheel Motor Temperature Indicator 944
Blower Fault Warning 944
Service Engine Indicator (CENSE) 944
Komatsu Engines with Centry™ Fuel Control 944
Hazard Warning Light Switch 944
Lamp Test Switch/Centry™ Diagnostic Test Switch 945
CENTRY™ FUEL SYSTEM DIAGNOSTICS 945
GENERAL OPERATION 945
DETERMINING FAULT CODES 945
EXITING THE DIAGNOSTICS MODE 947
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 947
BASIC PRECAUTIONS 947
OPERATION 947
INTERFACE MODULE 949
SECTION P LUBRICATION AND SERVICE INDEX 951
SECTION P2 LUBRICATION AND SERVICE INDEX 953
LUBRICATION AND SERVICE 955
GENERAL INFORMATION 955
HYDRAULIC TANK SERVICE 955
Adding Oil 955
COOLING SYSTEM 956
Radiator Filling Procedure 956
RESERVE ENGINE OIL SYSTEM – (OPTIONAL) 956
Reserve Oil Tank Filling Procedure (Remote Fill) 956
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS 958
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued) 959
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 960
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 960
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 961
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 962
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 963
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 964
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 965
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS 966
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS 966
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 967
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS 968
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 969
AUTOMATIC LUBRICATION SYSTEM 971
GENERAL DESCRIPTION 971
SYSTEM COMPONENTS 972
Filter Assembly 972
Hydraulic Motor and Grease Pump 972
Reservoir 972
Fixed Pressure Reducing Valve 972
Flow Control Valve 972
Solenoid Valve 973
Vent Valve 973
24VDC Lubrication Cycle Timer 973
Time Delay Module 973
Pump Cutoff Pressure Switch 973
Unloader Valve 973
Pressure Switch 973
Pressure Gauge 973
Manual Override Button 973
Injectors 973
SYSTEM OPERATION 976
Normal Operation 976
Pressure Failure Detection Circuits 977
GENERAL INSTRUCTIONS 978
LUBRICANT REQUIRED FOR SYSTEM 978
SYSTEM PRIMING 978
LUBRICANT PUMP 979
Pump Housing Oil Level 979
Pump Pressure Control 979
FILTER AND RESERVOIR 979
Filter Assembly Element 980
INJECTORS (SL-1 Series H) 980
Injector Specifications 980
Injector Adjustment 980
INJECTOR OPERATION 982
SYSTEM CHECKOUT 983
Lubrication Cycle Timer Check 983
Lubrication Cycle Timer Adjustment 984
PREVENTIVE MAINTENANCE INSPECTION 984
10 Hour Lubrication System Inspection 984
100 Hour Inspection 984
250 Hour Inspection 984
500 Hour Inspection 985
1000 Hour Inspection 985
PUMP REBUILD 986
Disassembly 986
Cleaning and Inspection 986
Assembly 988
VENT VALVE REBUILD 989
Disassembly and Assembly 989
SYSTEM TROUBLESHOOTING CHART 990
SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX 993
MOTORIZED WHEEL MAINTENANCE SCHEDULE 995
AXLE BOX 995
MOTORIZED WHEEL MAINTENANCE SCHEDULE 996
ARMATURE AREA 996
AT TIRE CHANGE 996
MOTORIZED WHEEL MAINTENANCE SCHEDULE 997
GENERATOR/ALTERNATOR 997
GRID BLOWER MOTOR 997
CONTROL EQUIPMENT CHECKS 997
MOTORIZED WHEEL MAINTENANCE SCHEDULE 998
VEHICLE OPERATIONS TESTS 998
SECTION R SYSTEM SCHEMATICS INDEX 999

DESCRIPTION:

Komatsu 730E Dump Truck Shop Manual CEBM020301 – PDF DOWNLOAD 

SERIAL NUMBERS A30539 – A30551

FOREWORD:

• This manual is written for use by the service technician. It is designed to help these persons to
  become fully knowl- edgeable of the truck and all its systems in order to keep it operating safely
  and efficiently. All operators and main- tenance 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 under- stood and followed when
  operating or repairing the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as
  well as other gen- eral information. The major portion of the manual pertains to disassembly,
  service, and reassembly. Each major serviceable component has a section in the shop manual.
  Disassembly of any component should only be done as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not
  necessarily depict a specific model.
• This manual shows dimensioning in metric units and in 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 manu- facturing bill of material for this unit. This complete number will be necessary
  for proper ordering of many service parts and/or warranty consideration.
• The GVW is what determines the load on the drive train, frame, tires, and other components. The
  vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
  (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload.
  To determine allowable payload, fill all lubricants and fuel tank to the proper level. Weigh the
  truck and record this value. Subtract it from the GVW to determine the allowable payload.

S.V 12/12/24