Komatsu 730E Dump Truck Shop Manual CEBM025700 PDF

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Komatsu 730E Dump Truck Shop Manual CEBM025700 – PDF DOWNLOAD

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Komatsu 730E Dump Truck Shop Manual CEBM025700 – PDF DOWNLOAD 

Language : English
Pages : 1046
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 730E Dump Truck Shop Manual CEBM025700 – PDF DOWNLOAD 

SERIAL NUMBERS A30620, A30622 – A30632

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.
• The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design
  and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload.

TABLE OF CONTENTS:

Komatsu 730E Dump Truck Shop Manual CEBM025700 – PDF DOWNLOAD 

SERIAL NUMBERS A30620, A30622 – A30632

COVER 0
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
MAJOR COMPONENT DESCRIPTION 11
SPECIFICATIONS 13
Komatsu SSA16V159 13
SECTION A3 GENERAL SAFETY AND OPERATION INDEX 15
GENERAL SAFETY AND OPERATION 18
PERSONAL SAFETY 18
Safety Rules 18
Truck Safety Features 18
Clothing And Personal Items 18
Unauthorized Modification 18
Leaving The Operator’s Seat 18
Mounting And Dismounting 19
Fire Extinguishers And First Aid Kits 19
Precautions For High Temperature Fluids 19
Asbestos Dust Hazard Prevention 20
Fire Prevention For Fuel And Oil 20
ROPS Precautions 20
Preventing Injury From Work Equipment 20
Precautions For Optional Attachments 20
Precautions When Starting The Machine 21
PRECAUTIONS FOR TRUCK OPERATION 21
Safety Is Thinking Ahead 21
Safety At The Work Site 21
Fire Prevention 21
Preparing For Operation 21
Ventilation For Enclosed Areas 21
Mirrors, Windows, And Lights 22
In The Operator’s Cab – Before Starting The Engine 22
Seat Belts 22
OPERATING THE MACHINE 22
Starting The Engine 22
Truck Operation – General 23
Traveling In The Truck 23
Precautions When Traveling In Reverse 23
Traveling On Slopes 24
Ensuring Good Visibility 24
Operating On Snow 24
Avoid Damage To The Dump Body 24
Driving Near High-Voltage Cables 24
When Loading The Truck 24
When Dumping 24
Working On Loose Ground 25
Parking The Machine 25
TOWING 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump-Starting With Booster Cables 26
Jump Starting With Receptacles 26
PRECAUTIONS FOR MAINTENANCE 27
BEFORE PERFORMING MAINTENANCE 27
Stopping The Engine Before Service 27
Warning Tag 27
Proper Tools 27
Securing The Dump Body 27
DURING MAINTENANCE 28
Personnel 28
Attachments 28
Working Under The Machine 28
Keeping The Machine Clean 28
Rules To Follow When Adding Fuel Or Oil 28
Radiator Coolant Level 28
Use Of Lighting 28
Precautions With The Battery 29
Handling High-Pressure Hoses 29
Precautions With High-Pressure Oil 29
Maintenance Near High Temperatures And High Pressures 29
Rotating Fan And Belts 29
Waste Materials 29
TIRES 30
Handling Tires 30
Tire Maintenance 31
Storing Tires After Removal 31
ADDITIONAL JOB SITE RULES 32
WHEN REPAIRS ARE NECESSARY 33
OPERATING INSTRUCTIONS 34
PREPARING FOR OPERATION 34
SAFETY IS THINKING AHEAD 34
WALK AROUND INSPECTION 34
ENGINE START-UP 38
AFTER ENGINE HAS STARTED 39
EMERGENCY STEERING SYSTEM 40
Operation 40
Pre-Operation Testing 40
Additional Guidelines 41
MACHINE OPERATION SAFETY PRECAUTIONS 41
LOADING 42
HAULING 42
PASSING 43
DUMPING 43
To Raise The Dump Body: 43
To Lower The Dump Body: (When dumping over a berm or into a crusher): 44
To Lower The Dump Body (When dumping on flat ground): 44
TOWING 45
Towing Procedure 45
SAFE PARKING PROCEDURES 46
ENGINE SHUTDOWN PROCEDURE 46
DELAYED ENGINE SHUTDOWN PROCEDURE 46
SUDDEN LOSS OF POWER 47
SECTION A4 WARNINGS AND CAUTIONS 49
TORQUE TABLES AND CONVERSION CHARTS 59
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 59
SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX 69
STORAGE AND IDLE MACHINE PREPARATION 71
SHORT TERM IDLE PERIODS 71
PREPARATION FOR STORAGE 72
REMOVAL FROM STORAGE 73
RECONDITIONING AN IDLE VEHICLE 74
ENGINE OPERATION 77
After The Engine Has Started 77
ENGINE STORAGE 78
Temporary Storage (30 Days Or Less) 78
Extended Storage (More Than 30 Days) 79
RESTORING AN ENGINE AFTER EXTENDED STORAGE 80
ELECTRIC DRIVE TRUCKS 81
Storing A Truck That Is Operational 81
Storing A Truck That Is Not Operational 82
Storing A Major Component 83
Periodic Inspections 83
Placing Equipment Into Service After Storage 83
SECTION B STRUCTURES INDEX 85
SECTION B2 STRUCTURAL COMPONENTS INDEX 87
STRUCTURAL COMPONENTS 89
LADDERS 89
Removal 89
Installation 89
GRILLE AND HOOD 90
Removal 90
Installation 90
RIGHT-HAND DECK 90
Removal 90
Installation 92
CENTER DECK 92
LEFT-HAND DECK 93
Removal 93
Installation 93
SECTION B3 DUMP BODY INDEX 95
DUMP BODY 97
Removal 97
Installation 98
BODY SLING 98
BODY PADS 99
BODY GUIDE 99
Adjustment 99
BODY POSITION INDICATOR 100
HOIST LIMIT SWITCH 100
ROCK EJECTORS 100
Inspection 100
SECTION B4 FUEL TANK INDEX 101
FUEL TANK 103
Removal 103
Repair 103
Cleaning 103
Installation 104
FUEL GAUGE SENDER 105
Removal 105
Installation 105
LOW FUEL SENDER 106
Removal 106
Installation 106
TANK BREATHER VALVE 107
Removal 107
Installation 107
Disassembly 107
Assembly 107
FUEL RECEIVER (WIGGINS QUICK FILL) 108
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL) 109
SECTION C ENGINE INDEX 111
SECTION C2 POWER MODULE INDEX 113
POWER MODULE 115
GENERAL INFORMATION 115
POWER MODULE SERVICE 116
Removal 116
Installation 120
SECTION C3 COOLING SYSTEM INDEX 123
COOLING SYSTEM 125
RADIATOR 125
Removal 125
Service 126
Installation 126
RADIATOR FILL PROCEDURE 127
RADIATOR REPAIR 127
Internal Inspection 127
External Cleaning 128
Disassembly 128
Cleaning and Inspection 129
Assembly 129
Additional Service Information 131
PRESSURE TESTING 131
COOLANT SYSTEM TROUBLESHOOTING 131
SECTION C4 POWER TRAIN INDEX 133
POWER TRAIN 135
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 135
General Information 135
Removal 135
ALTERNATOR INSTALLATION 137
Engine/Alternator Mating 137
Alternator Measurement 137
Engine End Play Measurement 138
Determining Shim Requirements 139
Installing Alternator On Engine 140
ENGINE 141
Removal 141
Installation 141
SECTION C5 AIR CLEANERS INDEX 143
AIR CLEANERS 145
OPERATION 145
SERVICING THE AIR CLEANERS 145
Replacing The Elements 146
AIR CLEANER ASSEMBLY CLEANING 147
Primary Element Cleaning 147
Precleaner Section Cleaning 149
AIR INTAKE TROUBLESHOOTING 150
SECTION C7 FAN DRIVE CLUTCH INDEX 151
FAN DRIVE CLUTCH 152
COMPONENTS 152
Input 152
Output 152
Stationary Components 153
OPERATIONAL MODES 154
Fully Engaged 154
Modulated Variable Speed 154
Fully Released 155
Lubricating and Cooling Oil 156
MAINTENANCE 157
TROUBLESHOOTING 158
Preliminary Checks 158
FIELD CHECK DIAGNOSIS 159
Preliminary Checks – Engine Off 159
Check Clutch Release 159
Check Clutch Lock-up 160
Overheating 160
Thermal Sensor and Solenoid Valve 161
On Truck Test 161
Off Truck Test 161
FAN CLUTCH DISASSEMBLY INSTRUCTIONS 166
REASSEMBLY OF THE FAN CLUTCH 173
INSPECTION OF PARTS 184
REBUILD TOOLS 188
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 189
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 191
24VDC ELECTRIC SUPPLY SYSTEM 193
ELECTRICAL SYSTEM DESCRIPTION 193
BATTERIES 193
Maintenance and Service 193
Troubleshooting 193
BATTERY CHARGING ALTERNATOR 195
24VDC ELECTRIC START SYSTEM 195
CRANKING MOTORS 195
Removal 195
Installation 196
CRANKING MOTOR TROUBLESHOOTING 196
Preliminary Inspection 197
No-Load Test 197
Interpreting Results of Tests 197
Disassembly 198
Cleaning and Inspection 198
Armature Servicing 199
Field Coil Checks 201
Field Coil Removal 201
Solenoid Checks 201
Test 201
Assembly 203
Pinion Clearance 204
MAGNETIC SWITCH 204
Coil Test 204
Electric Start System Wiring Diagrams 204
ENGINE PRELUB SYSTEM 205
OPERATION 205
Pressure Switch 205
Suction Line 205
Outlet Line 205
Check Valve 205
Solenoid Timer 205
TROUBLESHOOTING PRELUB STARTER CIRCUIT 207
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 211
24VDC ELECTRICAL SYSTEM COMPONENTS 213
PASSENGER SEAT BASE COMPARTMENT 213
COMPONENTS 213
Taillight Resistor Diode Assemblies 213
Inclinometer 213
Lubrication System Timer 213
Three Minute Idle Timer Components 213
Three Minute Idle Timer 215
Idle Timer Relay 215
Three Minute Idle Contactor 215
Three Minute Idle Circuit Test 215
Data Store Button 215
Komatsu Engine Diagnostic Connector (Centry) 215
Komatsu Engine Diagnostic Port (CENSE) 215
STATEX III Propulsion System Diagnostic Connector 215
Modular Mining Port (Optional) 215
Alarm Indicating Device (AID) System 216
Diode Matrix (Without Sound) 216
Diode Matrix (With Sound) 217
Hot Switch Inverter 217
Hot Switch Inverter Card (Slot 4) (Not Used) 217
Temperature 217
Oil Level 217
Temperature and Latch 217
Coolant Level/Flasher 218
Lamp Test 218
BATTERY EQUALIZER BOX 218
Troubleshooting 218
BODY POSITION SWITCHES 220
Proximity Switch Operation 220
Body-Up Switch Adjustment 221
Hoist Limit Switch Adjustment 221
24-VOLT RELAY AND DIODE BOARDS 223
RELAY BOARDS 224
Description 224
SERVICE 224
To Replace A Relay: 224
To Replace A Circuit Breaker: 224
To Replace A Circuit Panel Card 225
Relay Board Components 225
Installing Additional Circuits 226
DIODE BOARD 1 227
Diode Testing 227
CIRCUIT BREAKERS 229
SECTION D11 KOMTRAX Plus COMPONENTS INDEX 231
VEHICLE HEALTH MONITORING SYSTEM (KOMTRAX Plus) 233
KOMTRAX Plus BASIC FEATURES 233
Gather Data 233
Convert and Record Data 234
Communicate Data to Off-Board Systems 234
USING THE KOMTRAX Plus SYSTEM 235
Basic Precautions 235
Turning the KOMTRAX Plus System On 235
Normal KOMTRAX Plus Operation 236
Turning the KOMTRAX Plus System Off 236
Downloading From the KOMTRAX Plus Controller 236
KOMTRAX Plus DATA ITEMS 237
Fault Codes 237
Machine History 237
KOMTRAX Plus History 238
Snapshots 238
Manual Snapshots 238
Trends 238
Histogram (Load Map) Data 240
Haul Cycle Data 241
Alarm and Snapshot Triggers 242
Satellite Features 244
KOMTRAX Plus DIAGNOSTIC FEATURES 244
Fault History 244
KOMTRAX Plus LED Digits 244
Light (10) PLM III communication 244
Light (11) OrbComm 244
KOMTRAX Plus COMPONENTS 245
KOMTRAX Plus CONTROLLER 245
Removal 246
Installation 246
OrbComm Controller 247
Removal 247
Installation 248
INTERFACE MODULE 248
Inputs 249
Outputs 249
Removal 249
Installation 249
COMPONENT LOCATION 250
Circuit Breakers 250
Temperature Sensors 251
Pressure Sensors 252
SECTION D12 KOMTRAX Plus SOFTWARE INDEX 253
KOMTRAX Plus SOFTWARE 255
Necessary Software 255
Necessary Tools 256
KOMTRAX Plus TOOL BOX INSTALLATION 256
KOMTRAX Plus SETTING TOOL INSTALLATION 257
KOMTRAX Plus INITIALIZATION PROCEDURE 257
Preliminary Checks 257
Initialization Steps 257
Select Operation 258
KOMTRAX Plus Setting Function 258
Machine Information Setting(1) 258
Machine Information Setting(2) 258
Date and Time Setting 259
GCC Setting 259
Setting Summary 259
KOMTRAX Plus SNAPSHOT PROCEDURE 260
KOMTRAX Plus DOWNLOAD 260
KOMTRAX Plus FTP UPLOAD 261
LOCATION OF DOWNLOAD FILES 262
INSTALLING FLASHBURN PROGRAM 263
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 263
INSTALLING REALTIME MONITOR SOFTWARE PROGRAM 264
WHEN REPLACING A KOMTRAX Plus CONTROLLER 264
To Set: Date and time, satellite, payload meter 266
Review Setting Information 268
SECTION D13 KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING INDEX 269
KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING 272
KOMTRAX Plus CHECKOUT PROCEDURE 272
General 272
Structure and Purpose 273
Necessary Equipment: 273
KOMTRAX Plus SYSTEM CHECKOUT 273
Preliminary 273
Checking Inputs To The Interface Module 274
For 930E & 960E trucks only: 276
For 830E trucks only: 276
Checking Outputs From The Interface Module 277
For 830E only: 277
For 930E & 960E only: 277
KOMTRAX Plus CONTROLLER CHECKOUT 277
TROUBLESHOOTING 278
Communications Networks 278
Coaxial Cable 278
KOMTRAX Plus COMPONENTS 279
KOMTRAX Plus Controller 279
OrbComm Controller 280
Interface Module 280
FAULT CODES 281
Fault History 281
KOMTRAX Plus LED Display Fault Codes 282
Chassis Fault Codes 283
Engine Fault Codes 287
FAULT TREE ANALYSIS 293
Unable to connect to KOMTRAX Plus from laptop PC 293
Flashing Error Code N4-23 (PLM III Communications Fault) 294
Flashing Error Code N4-22 (Engine Communications Fault) 295
No Data Received By WebCARE 296
Coaxial Cable Troubleshooting 297
SECTION D14 KOMTRAX PLUS FORMS INDEX 299
KOMTRAX PLUS FORMS 301
KOMTRAX PLUS INITIALIZATION CHECK LIST 301
KOMTRAX PLUS DATA DOWNLOAD 302
KOMTRAX PLUS INITIALIZATION CHECK LIST 303
KOMTRAX PLUS INITIALIZATION FORM 305
SECTION D35 PAYLOAD METER III INDEX 307
OPERATION SECTION 312
Introduction 312
Data Summary 312
Data Gathering 312
COMPONENT DESCRIPTION 313
System Diagram 313
Suspension Pressure Sensors 313
Inclinometer 313
Operator Display 313
Operator Switch 314
Speed Input 314
Body-Up Switch 314
Brake Lock Switch 314
Payload Meter 314
Communications Ports 314
Key Switch Input 315
Payload Meter Power 315
Load Lights 315
Wiring and Termination 316
TCI Outputs 316
OPERATOR’S DISPLAY AND SWITCH 317
Reading the Speedometer 317
Reading the Load Display 317
Using the Operator ID 317
Using the Load and Ton Counter 317
Total Ton Counter 317
Total Load Counter 318
Clearing the Counters 318
Viewing Live Sensor Data 318
Other Display Messages 318
PAYLOAD OPERATION & CALCULATION 319
Description of Haul Cycle States 319
Haul Cycle Description 319
Load Calculation 320
Carry Back 320
Measurement Accuracy 320
SOURCES FOR PAYLOAD ERROR 320
Payload Error 320
Loading Conditions 321
Pressure Sensors 321
Swingloads 321
Speed and Distance 321
HAUL CYCLE DATA 321
Haul Cycle Warning Flags 323
Frame Torque Data 324
Sprung Weight Data 324
Maximum Speed Data 324
Alarm Records 324
Fault Code Data 325
PC SOFTWARE OVERVIEW 326
System Configuration 326
Installing the PLMIII Software 326
DOWNLOADING DATA 327
PLM III SYSTEM CONFIGURATION 328
Starting Communications 328
Displayed Payload Units 328
Time Units 328
Connection Menu 328
Connecting to the Payload Meter 329
Configure the Payload Meter 329
Setting the Date and Time 329
Setting the Truck Type 330
Setting the Gauge Display Units 330
Setting the Frame Serial Number 330
Setting the Truck Number 330
Setting the Komatsu Distributor 330
Setting the Komatsu Customer 330
Setting the Overload Speed Limit Function 331
Clean Truck Tare 332
Inclinometer Calibration 332
DATA ANALYSIS 333
Creating a Query 333
Sorting on Truck Unit Number 333
Sorting on Truck Type 333
Sorting on Date Range 334
Sorting on Time Range 334
Payload Detail Screen 335
Creating Reports 335
Summary – one page report 336
Detailed – multi-page report 336
Creating Graphs 337
Exporting Data 337
CSV Export 337
Compressed 338
Importing Data 339
Deleting Haul Cycle Records 339
Viewing Alarms 340
Deleting Alarm Records 340
TROUBLESHOOTING SECTION 341
TROUBLESHOOTING 341
Viewing Active Alarms 341
Real-Time Data Display 341
Testing the Payload Lights 341
Creating Log Files of Inputs 342
Daily Inspections 342
Periodic Maintenance 342
Abnormal Displays at Power-Up 343
No Payload Display When Key Switch is Turned ON 344
No Display on Speedometer 345
No Display on Operator Display 345
No Communications With PC 346
Load Lights Don’t Light During Loading 347
Load Lights Remain ON 348
Load Lights Remain ON During Dumping 348
Display Doesn’t Clear When The Load Is Dumped 348
Calibration Problems 349
Alarm 1 – Left Front Pressure High 350
Alarm 2 – Left Front Pressure Low 350
Troubleshoot Wiring to Left Front Suspension 350
Alarm 3 – Right Front Pressure High 351
Alarm 4 – Right Front Pressure Low 351
Troubleshoot Wiring to Right Front Suspension 351
Alarm 5 -Left Rear Pressure High 352
Alarm 6 – Left Rear Pressure Low 352
Troubleshoot Wiring to Left Rear Suspension 352
Alarm 7 – Right Rear Pressure High 353
Alarm 8 – Right Rear Pressure Low 353
Troubleshoot Wiring to Right Rear Suspension 353
Alarm 9 – Inclinometer High 354
Alarm 10 – Inclinometer Low 354
Troubleshoot Inclinometer Wiring 354
Alarm 13 – Body Up Input Failure 355
Alarm 16 – Memory Write Failure 356
Alarm 17 – Memory Read Failure 356
Alarm 18 356
Alarm 19 356
Alarm 22 356
Operator Switch Doesn’t Work 357
Alarm 26 – User Switch Fault – SELECT 357
Alarm 27 – User Switch Fault – SET 357
Connector Map 358
Connectors 359
PLMIII CHECK OUT PROCEDURE 360
General Description 360
Tools Required 360
Checkout Procedure 360
PLMIII CHECKOUT PROCEDURE CONFIRMATION 364
Flashburn Programming 364
Confirmation Checklist 366
SECTION E ELECTRICAL PROPULSION INDEX 367
SECTION E2 ELECTRICAL PROPULSION COMPONENTS INDEX 369
ELECTRICAL PROPULSION COMPONENTS 373
GENERAL SYSTEM DESCRIPTION 373
CONTROL SYSTEM 373
System Operation 374
FL275 Panel 375
CARD REPLACEMENT 376
Removal 376
Installation 376
Card Repair 376
Panel Wiring 376
COMPUTER DESCRIPTION 377
Microprocessor 377
Download Capability 377
SOFTWARE 377
Base Monitor Program 377
Runtime Monitor Program – OBJ Running Code 377
Configuration Software – CFG 378
PTU – Portable Test Unit Code 378
System Regulation 378
Propulsion 379
Retarding 379
TWO-DIGIT DISPLAY PANEL 380
The Coded Number 380
Events 380
Frames 381
Windows 381
System Categories 381
Limits On Resetting Faults 381
NA Faults 382
Event Sequence 382
Resetting Events 382
Event Descriptions 382
Subcode Descriptions 382
2-DIGIT DISPLAY PANEL SUBCODES 390
PORTABLE TEST UNIT (PTU) 393
DESCRIPTION 393
Operational Hints 393
SOFTWARE INSTALLATION PREPARATION 394
HARD DISK SPACE REQUIREMENTS 394
SOFTWARE INSTALLATION ON PTU 394
PTU/Truck Communication Problems 395
THE MAIN MENU 396
Quit Menu 396
PTU Talk To Truck 396
View PTU Saved Files 396
List Stat Data Files 396
Truck Setup (CFG) 396
Select Truck Setup 396
Update CFG Version 396
Change PTU Password 396
CONFIGURATION (CFG) FILE CONVERSION 398
Conversion Procedure 398
Convert Old CFG files for New software 399
STATEX CONFIGURATION FILES 402
0) Source Directory: 402
1) Select A Truck Configuration 403
2) View Truck Configuration: Data Curves 404
3) Change/View Serial and Model Numbers 405
4) View Options 405
5) Change/View Truck Specifics 407
6) Change/View Overspeeds 409
7) Save a Truck Configuration, filename: 410
8) Save Directory: 411
CHANGE PTU PASSWORD 412
PROGRAMMING THE TRUCK 413
Connect PTU to the Truck 413
Select Configuration File 413
Activate The PTU Mode 413
Check Object Code Version 414
Download Configuration Files 415
Date And Time 416
Event Data 417
Statistical Data 419
View Counters 419
View Profiles 419
Upload Statistical Data To A File 419
Statistical Data Codes – Counters 420
STATISTICAL DATA CODES – COUNTERS 421
STATISTICAL DATA CODES – PROFILES 426
TRUCK SPECIFIC INFORMATION 430
Temporary Truck Settings 431
MISCELLANEOUS FEATURES 432
Saving Data 432
PTU Abbreviations 433
Other Menu Selections 433
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 434
ALTERNATOR 434
ELECTRIC WHEEL MOTORS 434
RETARDING GRIDS 434
ELECTRONIC ACCELERATOR AND RETARD PEDALS 434
Removal 434
Installation 434
Disassembly 435
Reassembly 435
COOLING BLOWER WARNING SYSTEM 435
Operation 435
Test 435
Removal 436
Installation 436
ELECTRICAL CONTROL CABINET 437
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 442
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 443
SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX 445
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 449
GENERAL INFORMATION 449
COMMUNICATIONS PORT CHECK 450
PTU Hookup 450
4 0 SEQUENCE TESTS – (ENGINE NOT ON) 451
Preparation and Setup 451
CONTROL SYSTEM SELF-TEST 452
4 1 THROTTLE SYSTEM CHECK AND ADJUSTMENT 452
4 2 RETARD SYSTEM CHECK AND ADJUSTMENT 453
PTU Setup 453
4 3 REVERSER AND PROPULSION CONTACTORS CHECK 454
4 4 NOT USED 455
4 5 RETARD CONTACTORS OPERATION CHECK 455
4 6 GROUND FAULT SENSING CHECK 455
4 7 GROUND FAULT IN RETARD OPERATION CHECK 456
4 8 OVERRIDE OPERATION CHECK 456
4 9 ANTI-REVERSAL FUNCTION (AR) CHECK 457
4 10 OVERSPEED RETARD OPERATION CHECK 457
4 11 HOIST INTERLOCK OPERATION CHECK 458
4 12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK 458
Return to Main Menu 458
5 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 459
5 1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU 459
5 2 DIGITAL INPUT CHECKS 460
5 3 DIGITAL OUTPUT CHECKS 461
6 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 465
6 1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU 465
6 2 ANALOG INPUT CHECKS 466
6 3 FREQUENCY INPUT CHECKS 470
Return to Main Menu 471
7 0 SPEED EVENT CHECKS 471
Preparation and Setup 471
Setup PTU 471
7 1 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK 472
7 2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK 472
7 3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK 472
7 4 OTHER SPEED EVENTS CHECKS 472
Return to Main Menu 472
8 0 RETARD SPEED CONTROL SYSTEM CHECK 473
Preparation and Setup 473
Setup PTU 473
8 1 OVERSPEED PICKUP AND DROPOUT CHECK 473
8 2 RETARD POT MAXIMUM SETTING CHECK 473
8 3 RETARD POT MINIMUM SETTING CHECK 473
8 4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL 474
Return to Main Menu 474
9 0 LOAD TEST USING TRUCK RETARD GRIDS 474
Setup and Preparation 474
PTU Setup 474
9 1 LOAD TEST 475
10 0 MOTOR FIELD CURRENT CHECK IN RETARDING 475
Setup PTU 475
10 1 RETARD CHECK 476
11 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 477
11 1 BRAKE SYSTEM INTERLOCKS CHECK 477
Preparation 477
11 2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT 477
11 3 SYNC TRANSFORMER CHECKOUT 478
11 4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT 478
11 5 BATTERY BOOST ADJUSTMENT 478
11 6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST 478
11 7 MOTOR ROTATION TEST 479
11 8 GROUND FAULT CHECKS 479
12 0 MISCELLANEOUS CHARTS 480
12 1 WHEEL MOTOR GEAR RATIOS 480
12 2 MAXIMUM ALLOWABLE TRUCK SPEEDS 481
12 3 ENGINE 482
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX 483
SECTION G2 TIRES AND RIMS INDEX 485
TIRES AND RIMS 487
GENERAL INFORMATION 487
TIRES 487
Handling Tires 487
Tire Maintenance 488
Storing Tires After Removal 488
FRONT TIRES AND RIMS 489
Removal 489
Installation 490
REAR TIRES AND RIMS 491
Removal 491
Installation 492
RIM 493
Tire Removal 493
RIM AND TIRE PREPARATION 494
LUBRICANTS 494
TIRE INSTALLATION 495
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 497
FRONT WHEEL HUB AND SPINDLE 499
WHEEL HUB AND SPINDLE ASSEMBLY 499
Removal 499
Installation 501
Disassembly 502
Cleaning and Inspection 503
Assembly 503
Wheel Bearing Adjustment (Spindle Vertical) 506
Wheel Bearing Adjustment (Tire Mounted) 507
Spindle Removal Procedure (Optional) (off of the truck) 510
STEERING CYLINDERS AND TIE ROD 512
Spherical Bearing Wear Limits 512
Removal 513
Installation 515
Bearing Replacement 515
TOE-IN ADJUSTMENT 516
SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX 517
REAR AXLE HOUSING 519
PIVOT PIN 519
Removal 519
Installation 520
PIVOT EYE BEARING 520
Disassembly 520
Assembly 521
PIVOT EYE REPAIR 521
Removal 521
Disassembly 521
Bushing (New) 521
Pivot Eye Bore (New) 521
Assembly 521
Installation 522
ANTI-SWAY BAR 522
Removal 522
Installation 522
Disassembly 523
Cleaning and Inspection 523
Assembly 523
SECTION G5 REAR AXLE HOUSING INDEX 525
REAR AXLE HOUSING 527
REAR AXLE HOUSING 527
Removal 527
Installation 527
WHEEL MOTOR 527
Removal 527
Cleaning and Inspection 528
Installation 528
Maximum Cap Screw Usage 528
SECTION H SUSPENSIONS INDEX 531
SECTION H2 FRONT SUSPENSION INDEX 533
FRONT SUSPENSION 535
Removal 535
Installation 537
Angle Advance Tightening Procedure 538
Disassembly 539
Cleaning and Inspection 540
Assembly (Bearing Only) 540
Suspension Assembly (Complete) 540
SUSPENSION PRESSURE TEST 542
SECTION H3 REAR SUSPENSIONS INDEX 545
REAR SUSPENSIONS 547
Removal 548
Installation 550
Disassembly 550
Cleaning and Inspection 551
Assembly 551
SUSPENSION PRESSURE TEST 553
SECTION H4 OILING AND CHARGING PROCEDURES INDEX 555
OILING AND CHARGING PROCEDURE 557
GENERAL 557
EQUIPMENT LIST 557
Hydrair® Charging Kit 557
Installation of Charging Kit 557
Removal of Charging Kit 558
Support Blocks For Oiling and Charging Dimensions 558
FRONT SUSPENSION 559
Front Suspension Oiling 559
Front Suspension Nitrogen Charging 560
REAR SUSPENSION 562
Rear Suspension Oiling 562
Rear Suspension Nitrogen Charging 564
OIL AND NITROGEN SPECIFICATIONS CHART 565
SECTION J BRAKE CIRCUIT INDEX 567
SECTION J2 BRAKE CIRCUIT INDEX 569
BRAKE CIRCUIT 571
GENERAL DESCRIPTION 571
SERVICE BRAKE CIRCUIT 571
SECONDARY BRAKING AND AUTOMATIC APPLY 573
PARKING BRAKE CIRCUIT 573
Normal Operation (key switch on, engine on) 573
BRAKE LOCK CIRCUIT 574
WARNING CIRCUIT 574
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 577
BRAKE CIRCUIT COMPONENT SERVICE 579
BRAKE VALVE 579
Rebuild Criteria 579
Removal 579
Installation 581
Disassembly 583
Cleaning and Inspection 585
ASSEMBLY 585
Actuator Base Threaded Inserts 585
Boot and Cap 585
Valve Body Seal Installation 586
Regulator Sleeve O-Ring Installation 587
Actuator Plunger O-Ring Installation 587
Assembly of Valve 587
DIFFERENTIAL PRESSURE SWITCH 588
Disassembly 589
Cleaning and Inspection 589
Assembly 589
VALVE BENCH TEST AND ADJUSTMENT 589
Test Set Up Procedure 591
Brake Valve Output Pressure Adjustment 591
Differential Pressure Switch Test 592
Final Test and Adjustment 592
Installation Of Brake Pedal Actuator Assembly to Brake Valve 593
HYDRAULIC BRAKE ACCUMULATORS 595
Brake Accumulator Bleed-Down Procedure 595
Removal 595
Installation 597
Disassembly 597
Cleaning and Inspection 599
Assembly 599
Leak Testing 602
BRAKE ACCUMULATOR CHARGING 603
Temperature During Precharge 605
ACCUMULATOR STORAGE 605
Installation 606
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 607
BRAKE CIRCUIT CHECK-OUT PROCEDURE 609
EQUIPMENT REQUIRED 612
INITIAL SYSTEM SET-UP 613
Parking Brake 613
Service Brakes 614
Brake Lock/Secondary 614
Low Brake Pressure and Auto Apply 615
Reapplications 615
Differential Pressure Switch 615
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 617
The Brakes are Locked, Service, and/or Parking 617
Both Brake Circuits are Dragging 617
One Brake Circuit is Dragging 617
Brakes are Not Going to Full Pressure 617
A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off 617
Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released 618
Differential Pressure Warning Circuit is Not Operating 618
A Low Brake Pressure Warning Occurs When Brakes are Applied 618
Low Pressure Warning Circuit Not Operating Properly 618
Low Pressure Warning is On Even Though System Pressure is Correct 619
Low Pressure Warning Comes On and Pressure is Low 619
A Squeal is Heard When Controller is Operated 619
Output Pressure At Controller is Correct but Brakes are Not Applying 619
Brake Pressures Drift Excessively While Pedal is Held Steady 619
Oil is Leaking Around the Pedal Base 619
Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM 619
CHECK-OUT PROCEDURE 620
HYDRAULIC BRAKE SYSTEM DATA SHEET 620
SECTION J5 FRONT DISC BRAKES INDEX 623
FRONT DISC BRAKES 625
BRAKE CALIPER 625
Removal 625
Installation 626
Disassembly 627
Cleaning and Inspection 627
Assembly 629
BRAKE LINING 629
Replacement 629
FRONT SERVICE BRAKE BURNISHING 631
BRAKE BLEEDING PROCEDURE 632
REAR DISC BRAKES 0
REAR BRAKES 0
CALIPER, DISC, AND PARKING BRAKE 0
Removal 0
Installation 0
CALIPER PISTON 0
Piston Assembly Removal 0
Inspection 0
Piston Assembly Installation 0
FUNCTIONAL TEST OF PISTON ASSEMBLY 0
Return Spring Force 0
Built-In Clearance 0
Grip Force 0
Grip Force Measurement 0
Spring Force Measurement 0
Disassembly of Piston Assembly 0
Assembly of Piston Assembly 0
BENCH TEST 0
BRAKE LINING 0
Replacement 0
SERVICE BRAKE BURNISHING 0
SAFETY PRECAUTIONS 0
Rear Brake Burnishing 0
BRAKE BLEEDING PROCEDURE 0
Spring Force Measurement 0
SECTION J6 REAR BRAKES INDEX 633
REAR DISC BRAKES 635
REAR BRAKES 635
CALIPER, DISC, AND PARKING BRAKE 635
Removal 635
Installation 636
CALIPER PISTON 638
Piston Assembly Removal 638
Inspection 638
Piston Assembly Installation 639
FUNCTIONAL TEST OF PISTON ASSEMBLY 640
Return Spring Force 640
Built-In Clearance 640
Grip Force 642
Grip Force Measurement 643
Spring Force Measurement 645
Disassembly of Piston Assembly 646
Assembly of Piston Assembly 647
BENCH TEST 647
BRAKE LINING 648
Replacement 648
SERVICE BRAKE BURNISHING 651
SAFETY PRECAUTIONS 651
Rear Brake Burnishing 652
BRAKE BLEEDING PROCEDURE 653
Spring Force Measurement 654
SECTION J7 PARKING BRAKE INDEX 655
PARKING BRAKE 657
GENERAL INFORMATION 657
PARKING BRAKE CALIPER 657
Lining Thickness Inspection 657
Removal 658
Installation 658
Parking Brake Adjustment 659
Parking Brake Caliper Disassembly 660
Cleaning and Inspection 661
Parking Brake Caliper Assembly 662
PARKING BRAKE LINING REPLACEMENT 662
PARKING BRAKE BURNISH PROCEDURE 662
Lining Conditioning 662
BRAKE BLEEDING PROCEDURE 663
SECTION L HYDRAULIC SYSTEM INDEX 665
SECTION L2 HYDRAULIC SYSTEM INDEX 667
HYDRAULIC SYSTEM 669
GENERAL INFORMATION 669
HYDRAULIC SYSTEMS OPERATION 669
Hoist Circuit Operation 669
Steering Circuit Operation 671
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 675
HYDRAULIC SYSTEM COMPONENT REPAIR 677
HOIST PUMP 677
Removal 677
Installation 678
Disassembly 679
Inspection of Parts 682
Assembly 682
Troubleshooting Guide 686
HYDRAULIC TANK 687
Filling Instructions 687
Removal 688
Installation 688
HYDRAULIC TANK STRAINER AND DIFFUSER 689
Removal 689
Inspect and Clean 690
Installation 690
SECTION L4 STEERING CIRCUIT INDEX 691
STEERING CIRCUIT 693
STEERING CIRCUIT OPERATION 693
COMPONENT DESCRIPTION 694
Steering Control Valve 694
Unloader Valve 695
Bleed-Down Manifold Valve 695
Flow Amplifier 700
FLOW AMPLIFIER SYSTEM OPERATION 701
No Steer 701
Steering Left 703
Steering Right 705
No Steer, External Shock Load 707
Steering Pump 709
High Pressure Filter 709
Accumulators 709
Low Precharge Warning Switch 709
SECTION L5 STEERING CONTROL VALVE INDEX 711
STEERING CONTROL VALVE 713
Removal 713
Installation 714
STEERING CONTROL VALVE REBUILD 715
Disassembly 715
Cleaning and Inspection 716
Assembly 716
BRAKE / STEERING PUMP 720
Removal 720
Installation 722
Disassembly 723
Inspection of Parts 723
Assembly 725
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 727
STEERING CIRCUIT COMPONENT REPAIR 729
BLEED-DOWN MANIFOLD 729
Removal 729
Installation 729
ACCUMULATOR 730
Removal 730
Installation 731
Disassembly 732
Cleaning and Inspection 732
Assembly 733
Leak Testing 734
STEERING ACCUMULATOR CHARGING 735
Temperature During Precharge 738
ACCUMULATOR STORAGE 739
Installation 739
FLOW AMPLIFIER 740
Removal 740
Installation 740
Disassembly 741
Assembly 744
STEERING CYLINDERS 745
Disassembly 745
Piston Seal and Bearing Installation 745
Cylinder Assembly 745
Test 745
TROUBLESHOOTING CHART 748
SECTION L7 HOIST CIRCUIT INDEX 753
HOIST CIRCUIT 755
HOIST CIRCUIT OPERATION 755
COMPONENT DESCRIPTION 756
Hydraulic Tank 756
Hydraulic Pump 756
High Pressure Filter 756
Hoist Valve 756
Hoist Pilot Valve 757
Bleed-Down Manifold 758
Counterbalance Manifold 758
Hoist-Up Limit Solenoid 758
Pilot Operated Check Valve 758
HOIST VALVE OPERATION 760
Float Operation 760
Power Up Operation (Figure 7-6) 762
Hold Operation (Figure 7-7) 764
Power Down Operation (Figure 7-8) 766
Float Operation (Figure 7-9) 768
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 771
HOIST CIRCUIT COMPONENT REPAIR 773
HOIST VALVE 773
Removal 773
Installation 773
O-Ring Replacement 775
INLET SECTION 776
Disassembly 776
Cleaning and Inspection 777
Assembly 777
REAR SPOOL SECTION (WORK PORTS) 778
Disassembly 778
Cleaning and Inspection 780
Assembly 780
HOIST PILOT VALVE 782
Removal 782
Installation 782
Disassembly 783
Cleaning and Inspection 784
Assembly 784
HOIST UP LIMIT SOLENOID VALVE 785
HOIST CYLINDERS 786
Removal 786
Installation 787
Disassembly 789
Cleaning and Inspection 790
SS1143 Tightening Tool – Assembly Drawing 791
ASSEMBLY OF QUILL AND CYLINDER 791
Quill Installation 791
Installation Of Check Balls And Plugs In Quill 792
Assembly of Cylinder 794
Pressure Testing 795
COUNTERBALANCE MANIFOLD 795
SECTION L9 HIGH PRESSURE FILTERS INDEX 797
HYDRAULIC SYSTEM FILTERS 799
HOIST CIRCUIT FILTER 799
Filter Element Replacement 799
Removal 800
Installation 800
Indicator Switch 800
STEERING CIRCUIT FILTER 801
Filter Element Replacement 801
Removal 802
Installation 802
Indicator Switch 802
INDICATOR SWITCH 802
Test Procedure 802
SECTION L10 HYDRAULIC CHECK-OUT PROCEDURE INDEX 805
HYDRAULIC CHECK-OUT PROCEDURE 807
INITIAL START UP AND FLUSHING 807
COMPONENT CHECKOUT AND ADJUSTMENT 809
ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE 811
Counterbalance Valve Adjustment 813
Manifold Assembly 813
OIL CLEANLINESS CHECK 813
Oil Sampling Location On Truck 813
Oil Sampling Process and Cleanliness Criteria 814
DISABLED TRUCK DUMPING PROCEDURE 814
Hookup 814
Raising the Body 814
Lowering the Body 815
TROUBLESHOOTING CHART 816
Hoist Pump 816
Steering Circuit 818
Brake/Steering Pump 820
Flow Amplifier – Refer to Figure 10-9 822
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 823
SECTION M7 HEATER OPTIONS INDEX 825
ENGINE OIL HEATERS 827
GENERAL INFORMATION 827
TROUBLESHOOTING 827
HEATER ELEMENT 827
Removal 827
Installation 828
ENGINE COOLANT HEATER 829
GENERAL 829
Maintenance 829
HEATING ELEMENT 829
Removal 829
Installation 830
THERMOSTAT 830
Removal 830
Installation 830
HYDRAULIC OIL HEATERS 831
GENERAL INFORMATION 831
TROUBLESHOOTING 831
HEATER ELEMENT 831
Removal 831
Installation 832
SECTION M8 SPECIAL TOOLS INDEX 833
SPECIAL TOOLS 834
SEAL INSTALLATION RING 838
HYDRAULIC SYSTEM VACUUM PUMP 839
RADIATOR SHUTTERS 0
OPERATION 0
Hydraulic Circuit 0
Electrical Circuit: 0
MAINTENANCE AND REPAIR 0
TROUBLESHOOTING 0
Hydraulic Troubleshooting 0
Electrical Troubleshooting 0
SECTION M19 RADIATOR SHUTTERS INDEX 843
RADIATOR SHUTTERS 845
OPERATION 845
Hydraulic Circuit 845
Electrical Circuit: 846
MAINTENANCE AND REPAIR 846
TROUBLESHOOTING 847
Hydraulic Troubleshooting 850
Electrical Troubleshooting 852
SECTION N OPERATOR’S CAB INDEX 853
SECTION N2 TRUCK CAB INDEX 855
TRUCK CAB 857
TRUCK CAB 857
Description 857
Removal 858
Installation 860
CAB DOOR 860
Removal 860
Installation 861
Door Adjustment 861
Door Jam Bolt Adjustment 861
Door Handle Plunger Adjustment 863
Replace Door Glass 864
Replace Door Window Regulator 868
Replace Door Handle or Latch Assembly 868
Door and Door Hinge Seal Replacement 869
Door Opening Seal Removal 869
Installation 869
GLASS REPLACEMENT 870
Adhesive-Bonded Windows 870
Recommended Tools/Supplies 870
Replacement Procedure 870
Windshield and Rear Glass 871
Removal 871
Installation 872
REMOVAL AND INSTALLATION OF OPERATOR SEAT 873
Inspection 873
Removal 873
Installation 873
REMOVAL AND INSTALLATION OF PASSENGER SEAT 874
Removal 874
Installation 874
SECTION N3 CAB COMPONENTS INDEX 875
CAB COMPONENTS 877
WINDSHIELD WIPERS 877
WIPER MOTOR REPLACEMENT 877
Removal 877
Installation 877
WIPER ARM REPLACEMENT 877
Removal 877
Installation 878
WIPER LINKAGE REPLACEMENT 878
Removal 878
Installation 879
WINDSHIELD WASHER 879
Operation 879
Service 879
SECTION N4 OPERATOR COMFORT INDEX 881
OPERATOR COMFORT 883
HEATER / AIR CONDITIONER 883
Fan Speed Control Knob 883
Temperature Control Knob 883
Air Flow Directional Knob 883
Heater/Air Conditioner Vents 884
COMPONENTS 884
Fuse and Circuit Breaker 884
Relays 884
Heater Core 884
Fan Motor And Speed Control 885
Actuators 885
Cab Air Filter 885
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 888
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 888
PRINCIPLES OF REFRIGERATION 888
Air Conditioning 888
Refrigeration – The Act Of Cooling 889
The Refrigeration Cycle 889
AIR CONDITIONER SYSTEM COMPONENTS 890
Compressor (Refrigerant Pump) 890
Service Valves 890
Condenser 890
Receiver-Drier 890
Expansion Block Valve 891
Accumulator 891
Evaporator 891
ELECTRICAL CIRCUIT 892
Thermostat 892
Compressor Clutch 892
Trinary™ Switch 893
SYSTEM SERVICING 894
SERVICE TOOLS AND EQUIPMENT 895
Recovery/Recycle Station 895
Leak Detector 895
Service Valves 896
Vacuum Pump 896
Manifold Gauge Set 897
Installing Manifold Gauge Set 898
Purging Air From Service Hoses 898
SYSTEM PERFORMANCE TEST 899
SYSTEM OIL 900
Handling and Reusing PAG Oil 900
Oil Quantity 900
Checking System Oil 900
REFRIGERANT 901
Recycled Refrigerant 901
Reclaimed Refrigerant 901
Refrigerant Quantity 901
R-134a Refrigerant Containers 902
SYSTEM LEAK TESTING 902
Electronic Leak Detector 903
Tracer Dyes 903
Soap and Water 903
RECOVERING AND RECYCLING THE REFRIGERANT 903
Draining Oil from the Previous Recovery Cycle 903
Performing the Recovery Cycle 903
Performing the Recycling Procedure 904
Evacuating and Charging the A/C System 904
SYSTEM REPAIR 904
System Flushing 904
A/C DRIVE BELT CHECKOUT PROCEDURE 905
Pulley Alignment 905
Belt Tension Check 905
COMPONENT REPLACEMENT 907
Hoses and Fittings 907
Lines 907
Expansion Valve 907
Receiver-Drier 907
Thermostat 907
Compressor 908
Accumulator 908
Clutch 908
Servicing the Compressor Clutch 909
Pulley Removal 911
Clutch Coil Check 912
Pulley Installation 912
Clutch Assembly Installation 912
EVACUATING THE SYSTEM 914
CHARGING THE A/C SYSTEM 916
TROUBLESHOOTING 917
Preliminary Checks 917
Diagnosis Of Gauge Readings And System Performance 917
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 918
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 924
SECTION N5 OPERATOR CONTROLS AND EQUIPMENT INDEX 925
OPERATOR CAB AND CONTROLS 927
STEERING WHEEL AND CONTROLS 928
HORN BUTTON 928
TILT/TELESCOPE LEVER 928
M ULTI-FUNCTION TURN SIGNAL SWITCH 928
Turn Signal Operation 928
High Beam Headlight Operation 928
Windshield Wiper Operation 928
STEERING COLUMN 929
Removal 929
Inspection 929
Installation 930
STEERING WHEEL 930
Removal 930
Installation 930
PEDALS 932
SERVICE BRAKE PEDAL 932
DYNAMIC RETARDER PEDAL 932
Optional – Dual Function/Single Pedal 932
THROTTLE PEDAL 932
GRADE/SPEED WARNING CHART 933
OVERHEAD PANEL CONTROLS AND COMPONENTS 933
RADIO SPEAKERS 933
WARNING ALARM BUZZER 933
CAB RADIO 933
WARNING LIGHTS DIMMER CONTROL 933
WARNING/STATUS INDICATOR LIGHT PANEL 933
AIR CLEANER VACUUM GAUGES 933
WINDSHIELD WIPERS 933
TRUCK CONTROLS 934
F-N-R Selector Switch 934
Hoist Control Lever 935
CONSOLE SWITCHES AND CONTROLS 935
Ashtray 935
Cigarette Lighter 935
Left-Hand Window Control Switch 935
Right-Hand Window Control Switch 935
Engine Shutdown Switch 935
Override Switch 935
Retard Speed Control (RSC) Switch 936
Retard Speed Control (RSC) Dial 936
Statex III Download Port 937
Engine Diagnostic Port (CENSE) 937
Modular Mining Port 937
Passenger Seat 937
Engine Diagnostic Connectors 937
Engine Diagnostics Connector 937
Data Store Button 937
PAYLOAD METER 937
Payload Meter Download Connector 937
OPERATOR’S SEAT 938
Seat Belts 938
Adjustment 938
INSTRUMENT PANEL 939
CONTROL SYMBOLS 939
CONTROL SWITCHES AND GAUGES 940
Key Switch 940
Engine Shutdown Switch With Timer Delay 941
Fog Light Switch 941
Ladder Light Switch 941
Backup Light Switch 941
Panel Illumination Lights 941
Cab Air Conditioner/Heater Vents 941
Engine Cold Weather Starting Aid Switch 941
Rotating Beacon Light Switch 941
Heated Mirror Switch 941
Wheel Brake Lock Switch 942
Parking Brake Switch 942
Digital Tachometer 942
Right Turn Signal Indicator Light 943
High Beam Headlight Indicator Light 943
Left Turn Signal Indicator Light 943
Digital Speedometer/Payload Meter Display 943
Voltmeter Gauge 943
Engine Oil Pressure Gauge 943
Engine Water Temperature Gauge 943
Fuel Gauge 943
Engine Hourmeter 943
Headlight Switch 944
Panel Illumination Lights Dimmer Rheostat 944
Payload Meter Switch 944
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL 945
DESCRIPTION OF INDICATOR SYMBOLS 945
INDICATOR LIGHT FUNCTIONS 946
A1 High Hydraulic Oil Temperature 946
B1 Low Steering Pressure 946
C1 Low Accumulator Precharge Pressure 947
D1 Electric System Fault 947
E1 Low Brake Pressure 947
A2 Low Hydraulic Tank Level 947
B2 Automatic Lubrication System Pressure 947
C2 Circuit Breaker Tripped 947
D2 Hydraulic Oil Filter Monitor 948
E2 Low Fuel 948
A3 Parking Brake 948
B3 Service Brake 948
C3 Body Up 948
D3 Dynamic Retarding 948
E3 Stop Engine 948
A4 Not Used 949
B4 Manual Backup Lights 949
C4 Engine Shutdown Timer 949
D4 Retard Speed Control (RSC) 949
E4 Check Engine 949
A5 Service Engine Indicator (AEM) 949
B5 High Wheel Motor Temperature 949
C5 Blower Fault 949
D5, E5, A6, B6, and C6 Not Used 949
D6 Service Engine (CENSE) 949
E6 Not Used 949
Komatsu Engines w/Centry™ Fuel Control 950
Hazard Warning Light Switch 950
Lamp Test Switch/Centry™ Diagnostic Test Switch 950
REAR AXLE LIGHT BAR 951
Backup Lights 951
Retard Lights 951
Brake Light 951
Backup Alarm 951
KOMTRAX Plus 952
Operation 952
Interface Module 954
Basic Precautions 954
CENTRY™ FUEL SYSTEM DIAGNOSTICS 955
GENERAL OPERATION 955
DETERMINING FAULT CODES 955
EXITING THE DIAGNOSTICS MODE 956
SECTION P LUBRICATION AND SERVICE INDEX 957
SECTION P2 LUBRICATION AND SERVICE INDEX 959
LUBRICATION AND SERVICE 961
GENERAL INFORMATION 961
HYDRAULIC TANK SERVICE 961
Adding Oil 961
COOLANT LEVEL CHECK 962
Radiator Filling Procedure 962
Coolant Specifications 962
Unacceptable Practices 962
WHEEL MOTOR SERVICE 962
RESERVE ENGINE OIL SYSTEM (Optional) 963
Reserve Oil Tank Filling Procedure (Remote fill) 963
Inline Screen 963
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS 965
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued) 966
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 967
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 967
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 968
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 969
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 970
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 971
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 972
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS 973
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS 973
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 974
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS 975
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 977
AUTOMATIC LUBRICATION SYSTEM 979
GENERAL DESCRIPTION 979
SYSTEM COMPONENTS 980
Filter Assembly 980
Hydraulic Motor and Grease Pump 980
Reservoir 980
Fixed Pressure Reducing Valve 980
Flow Control Valve 980
Solenoid Valve 981
Vent Valve 981
24VDC Lubrication Cycle Timer 981
Time Delay Module 981
Pump Cutoff Pressure Switch 981
Unloader Valve 981
Pressure Switch 981
Manual Override Button 981
Injectors 981
SYSTEM OPERATION 984
Normal Operation 984
Pressure Failure Detection Circuits 985
GENERAL INSTRUCTIONS 986
LUBRICANT REQUIRED FOR SYSTEM 986
SYSTEM PRIMING 986
LUBRICANT PUMP 987
Pump Housing Oil Level 987
Pump Pressure Control 987
FILTER AND RESERVOIR 987
Filter Assembly Element 988
INJECTORS (SL-1 Series H) 988
Injector Specifications 988
Injector Adjustment 988
INJECTOR OPERATION 990
SYSTEM CHECKOUT 991
Lubrication Cycle Timer Check 991
Lubrication Cycle Timer Adjustment 992
PREVENTIVE MAINTENANCE INSPECTION 992
10 Hour Lubrication System Inspection 992
100 Hour Inspection 992
250 Hour Inspection 992
500 Hour Inspection 993
1000 Hour Inspection 993
PUMP REBUILD 994
Disassembly 994
Cleaning and Inspection 994
Assembly 996
VENT VALVE REBUILD 997
Disassembly and Assembly 997
SYSTEM TROUBLESHOOTING CHART 998
MOTORIZED WHEEL MAINTENANCE SCHEDULE 0
AXLE BOX 0
MOTORIZED WHEEL MAINTENANCE SCHEDULE 0
ARMATURE AREA 0
AT TIRE CHANGE 0
MOTORIZED WHEEL MAINTENANCE SCHEDULE 0
GENERATOR/ALTERNATOR 0
GRID BLOWER MOTOR 0
CONTROL EQUIPMENT CHECKS 0
MOTORIZED WHEEL MAINTENANCE SCHEDULE 0
VEHICLE OPERATIONS TESTS 0
SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX 1001
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1003
AXLE BOX 1003
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1004
ARMATURE AREA 1004
AT TIRE CHANGE 1004
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1005
GENERATOR/ALTERNATOR 1005
GRID BLOWER MOTOR 1005
CONTROL EQUIPMENT CHECKS 1005
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1006
VEHICLE OPERATIONS TESTS 1006
SECTION R SYSTEM SCHEMATICS INDEX 1007
EK5755 HYDRAULIC BRAKE SCHEMATIC 1009
EJ2729 HYDRAULIC SYSTEM SCHEMATIC 1010
EL8720 VHMS ELECTRICAL SCHEMATIC 1011
HE484 HVAC ELECTRICAL SCHEMATIC 1016
XS6500 ELECTRICAL SYSTEMS SCHEMATIC 1017

S.V 12/12/24