Komatsu 730E DUMP TRUCK Shop Manual CEBM026501 PDF

Description

Komatsu 730E DUMP TRUCK Shop Manual CEBM026501  – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E DUMP TRUCK Shop Manual CEBM026501  – PDF DOWNLOAD

Language : English
Pages : 10520
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 730E DUMP TRUCK Shop Manual CEBM026501  – PDF DOWNLOAD

• SERIAL NUMBERS 730E A30633 and up

COVER 1
SECTION A GENERAL INFORMATION 9
SECTION A2 MAJOR COMPONENT DESCRIPTION 11
Truck And Engine 11
Alternator (GTA-22) 11
Wheel Motors (788) 11
Blower 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
Suspension 11
SECTION A2 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
Use of Tie-Off Anchor During Maintenance and Repair 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
LUBRICATION CHART 57
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 59
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 60
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 60
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 61
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 62
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 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
Removal 97
Installation 98
SECTION B3 DUMP BODY INDEX 95
DUMP BODY 97
BODY PADS 99
Removal 99
Installation 99
Adjustment 100
BODY GUIDE 101
Securing The Dump Body 102
BODY POSITION INDICATOR 102
HOIST LIMIT SWITCH 102
BODY UP SWITCH 102
ROCK EJECTORS 103
Inspection 103
SECTION B4 FUEL TANK INDEX 105
FUEL TANK 107
Removal 107
Repair 107
Cleaning 107
Installation 108
FUEL GAUGE SENDER 109
Removal 109
Installation 109
LOW FUEL SENDER 110
Removal 110
Installation 110
TANK BREATHER VALVE 111
Removal 111
Installation 111
Disassembly 111
Assembly 111
FUEL RECEIVER (WIGGINS QUICK FILL) 112
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL) 113
SECTION C ENGINE 115
SECTION C2 POWER MODULE INDEX 117
POWER MODULE 119
GENERAL INFORMATION 119
POWER MODULE SERVICE 120
Removal 120
Installation 124
EXHAUST TUBE INSTALLATION 128
EXHAUST BLANKET INSTALLATION 128
SECTION C3 COOLING SYSTEM INDEX 129
COOLING SYSTEM 131
RADIATOR 131
Removal 131
Service 132
Installation 132
RADIATOR FILL PROCEDURE 133
RADIATOR REPAIR 133
Internal Inspection 133
External Cleaning 134
Disassembly 134
Cleaning and Inspection 135
Assembly 136
Additional Service Information 137
PRESSURE TESTING 137
COOLANT SYSTEM TROUBLESHOOTING 137
SECTION C4 POWER TRAIN INDEX 139
POWER TRAIN 141
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 141
General Information 141
Removal 141
ALTERNATOR INSTALLATION 143
Engine/Alternator Mating 143
Alternator Measurement 143
Engine End Play Measurement 144
Determining Shim Requirements 145
Installing Alternator On Engine 146
ENGINE 148
Removal 148
Installation 148
SECTION C5 AIR CLEANERS INDEX 149
AIR CLEANERS 151
OPERATION 151
SERVICING THE AIR CLEANERS 151
Replacing The Elements 152
AIR CLEANER ASSEMBLY CLEANING 153
Primary Element Cleaning 153
Precleaner Section Cleaning 155
AIR INTAKE TROUBLESHOOTING 156
SECTION C7 FAN DRIVE CLUTCH INDEX 157
FAN DRIVE CLUTCH 159
GENERAL DESCRIPTION 159
COMPONENTS 159
Input 159
Output 159
Stationary Components 160
OPERATIONAL MODES 161
Fully Engaged 161
Modulated Variable Speed 161
Fully Released 162
Lubricating and Cooling Oil 163
MAINTENANCE 164
TROUBLESHOOTING 165
Preliminary Checks 165
FIELD CHECK DIAGNOSIS 166
Preliminary Checks – Engine Off 166
Check Clutch Release 166
Check Clutch Lock-up 167
Overheating 167
Thermal Sensor and Solenoid Valve 168
On Truck Test 168
Off Truck Test 168
FAN CLUTCH DISASSEMBLY INSTRUCTIONS 173
REASSEMBLY OF THE FAN CLUTCH 180
INSPECTION OF PARTS 191
REBUILD TOOLS 195
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 197
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 199
24VDC ELECTRIC SUPPLY SYSTEM 201
ELECTRICAL SYSTEM DESCRIPTION 201
BATTERIES 201
Maintenance and Service 201
Troubleshooting 201
BATTERY CHARGING ALTERNATOR 203
24VDC ELECTRIC START SYSTEM 203
CRANKING MOTORS 203
Removal 203
Installation 204
CRANKING MOTOR TROUBLESHOOTING 204
Preliminary Inspection 205
No-Load Test 205
Interpreting Results of Tests 205
Disassembly 206
Cleaning and Inspection 206
Armature Servicing 207
Field Coil Checks 209
Field Coil Removal 209
Solenoid Checks 209
Test 209
Assembly 211
Pinion Clearance 212
MAGNETIC SWITCH 212
Coil Test 212
Electric Start System Wiring Diagrams 212
ENGINE PRELUB SYSTEM 213
OPERATION 213
Pressure Switch 213
Suction Line 213
Outlet Line 213
Check Valve 213
Solenoid Timer 213
TROUBLESHOOTING PRELUB STARTER CIRCUIT 215
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 219
24VDC ELECTRICAL SYSTEM COMPONENTS 221
PASSENGER SEAT BASE COMPARTMENT 221
COMPONENTS 221
Taillight Resistor Diode Assemblies 221
Inclinometer 221
Lubrication System Timer 221
Three Minute Idle Timer Components 221
Three Minute Idle Timer 223
Idle Timer Relay 223
Three Minute Idle Contactor 223
Three Minute Idle Circuit Test 223
Data Store Button 223
Komatsu Engine Diagnostic Connector (Centry) 223
Komatsu Engine Diagnostic Port (CENSE) 223
STATEX III Propulsion System Diagnostic Connector 223
Alarm Indicating Device (AID) System 224
Diode Matrix (Without Sound) 224
Diode Matrix (With Sound) 225
Hot Switch Inverter 225
Hot Switch Inverter Card (Slot 4) (Not Used) 225
Temperature 225
Oil Level 225
Temperature and Latch 225
Coolant Level/Flasher 226
Lamp Test 226
BATTERY EQUALIZER BOX 226
Troubleshooting 226
BODY POSITION SWITCHES 228
Proximity Switch Operation 228
Body-Up Switch Adjustment 229
Hoist Limit Switch Adjustment 229
24-VOLT RELAY AND DIODE BOARDS 231
RELAY BOARDS 232
Description 232
SERVICE 232
To Replace A Relay: 232
To Replace A Circuit Breaker: 232
To Replace A Circuit Panel Card 233
Relay Board Components 233
Installing Additional Circuits 234
DIODE BOARD 1 235
Diode Testing 235
CIRCUIT BREAKERS 237
SECTION D11 KOMTRAX Plus COMPONENTS INDEX 239
VEHICLE HEALTH MONITORING SYSTEM (KOMTRAX Plus) 241
KOMTRAX Plus BASIC FEATURES 241
Gather Data 241
Convert and Record Data 242
Communicate Data to Off-Board Systems 242
USING THE KOMTRAX Plus SYSTEM 243
Basic Precautions 243
Turning the KOMTRAX Plus System On 243
Normal KOMTRAX Plus Operation 244
Turning the KOMTRAX Plus System Off 244
Downloading From the KOMTRAX Plus Controller 244
KOMTRAX Plus DATA ITEMS 245
Fault Codes 245
Machine History 245
KOMTRAX Plus History 246
Snapshots 246
Manual Snapshots 246
Trends 246
Histogram (Load Map) Data 248
Haul Cycle Data 249
Alarm and Snapshot Triggers 250
Satellite Features 252
KOMTRAX Plus DIAGNOSTIC FEATURES 252
Fault History 252
KOMTRAX Plus LED Digits 252
Light (10) PLM III communication 252
Light (11) OrbComm 252
KOMTRAX Plus COMPONENTS 253
KOMTRAX Plus CONTROLLER 253
Removal 254
Installation 254
OrbComm Controller 255
Removal 255
Installation 256
INTERFACE MODULE 256
Inputs 257
Outputs 257
Removal 257
Installation 257
COMPONENT LOCATION 258
Circuit Breakers 258
Temperature Sensors 259
Pressure Sensors 260
Necessary Software 263
Necessary Tools 264
SECTION D12 KOMTRAX Plus SOFTWARE INDEX 261
KOMTRAX Plus SOFTWARE 263
Necessary Software 263
Necessary Tools 264
KOMTRAX Plus TOOL BOX INSTALLATION 264
KOMTRAX Plus SETTING TOOL INSTALLATION 265
KOMTRAX Plus INITIALIZATION PROCEDURE 265
Preliminary Checks 265
Initialization Steps 265
Select Operation 266
KOMTRAX Plus Setting Function 266
Machine Information Setting(1) 266
Machine Information Setting(2) 266
Date and Time Setting 267
GCC Setting 267
Setting Summary 267
KOMTRAX Plus SNAPSHOT PROCEDURE 268
KOMTRAX Plus DOWNLOAD 268
KOMTRAX Plus FTP UPLOAD 269
LOCATION OF DOWNLOAD FILES 270
INSTALLING FLASHBURN PROGRAM 271
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 271
INSTALLING REALTIME MONITOR SOFTWARE PROGRAM 272
WHEN REPLACING A KOMTRAX Plus CONTROLLER 272
To Set: Date and time, satellite, payload meter 274
Review Setting Information 276
SECTION D13 KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING INDEX 277
KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING 280
KOMTRAX Plus CHECKOUT PROCEDURE 280
General 280
Structure and Purpose 281
Necessary Equipment: 281
KOMTRAX Plus SYSTEM CHECKOUT 281
Preliminary 281
Checking Inputs To The Interface Module 282
For 930E & 960E trucks only: 284
For 830E trucks only: 284
Checking Outputs From The Interface Module 285
For 830E only: 285
For 930E & 960E only: 285
KOMTRAX Plus CONTROLLER CHECKOUT 285
TROUBLESHOOTING 286
Communications Networks 286
Coaxial Cable 286
KOMTRAX Plus COMPONENTS 287
KOMTRAX Plus Controller 287
OrbComm Controller 288
Interface Module 288
FAULT CODES 289
Fault History 289
KOMTRAX Plus LED Display Fault Codes 290
Chassis Fault Codes 291
Engine Fault Codes 295
FAULT TREE ANALYSIS 301
Unable to connect to KOMTRAX Plus from laptop PC 301
Flashing Error Code N4-23 (PLM Communications Fault) 302
Flashing Error Code N4-22 (Engine Communications Fault) 303
No Data Received By WebCARE 304
Coaxial Cable Troubleshooting 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 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 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
WHEEL STUD MAINTENANCE 489
REAR OUTER WHEEL STUD INSTALLATION 490
FRONT TIRES AND RIMS 491
Removal 491
Installation 492
REAR TIRES AND RIMS 493
Removal 493
Installation 494
RIM 495
Tire Removal 495
RIM AND TIRE PREPARATION 496
LUBRICANTS 496
TIRE INSTALLATION 497
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 499
FRONT WHEEL HUB AND SPINDLE 501
WHEEL HUB AND SPINDLE ASSEMBLY 501
Removal 501
Installation 503
Disassembly 504
Cleaning and Inspection 505
Assembly 505
Wheel Bearing Adjustment (Spindle Vertical) 508
Wheel Bearing Adjustment (Tire Mounted) 509
Spindle Removal Procedure (Optional) (off of the truck) 512
STEERING CYLINDERS AND TIE ROD 514
Spherical Bearing Wear Limits 514
Removal 515
Installation 517
Bearing Replacement 517
TOE-IN ADJUSTMENT 518
SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX 519
REAR AXLE HOUSING 521
PIVOT PIN 521
Removal 521
Installation 522
PIVOT EYE BEARING 522
Disassembly 522
Assembly 523
PIVOT EYE REPAIR 523
Removal 523
Disassembly 523
Bushing (New) 523
Pivot Eye Bore (New) 523
Assembly 523
Installation 524
ANTI-SWAY BAR 524
Removal 524
Installation 524
Disassembly 525
Cleaning and Inspection 525
Assembly 525
SECTION G5 REAR AXLE HOUSING INDEX 527
REAR AXLE HOUSING 529
REAR AXLE HOUSING 529
Removal 529
Installation 529
WHEEL MOTOR 529
Removal 529
Cleaning and Inspection 530
Installation 530
Maximum Cap Screw Usage 530
Removal 537
Installation 538
SECTION H SUSPENSIONS 533
SECTION H2 FRONT SUSPENSION INDEX 535
FRONT SUSPENSION 537
TURN-OF-THE-NUT Tightening Procedure 540
Upper Mounting Joint – 60° Advance 540
Lower Mounting Joint – 90° Advance 542
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 543
Bearing Structure Removal 543
Bearing Structure Installation 543
MAJOR SUSPENSION REBUILD 544
Disassembly 544
Assembly 545
PRESSURE TEST 547
SECTION H3 REAR SUSPENSIONS INDEX 549
REAR SUSPENSIONS 551
Removal 552
Installation 554
Disassembly 554
Cleaning and Inspection 555
Assembly 555
SUSPENSION PRESSURE TEST 557
SECTION H4 OILING AND CHARGING PROCEDURES INDEX 559
OILING AND CHARGING PROCEDURE 561
GENERAL 561
EQUIPMENT LIST 561
Hydrair® Charging Kit 561
Installation of Charging Kit 561
Removal of Charging Kit 562
Support Blocks For Oiling and Charging Dimensions 562
FRONT SUSPENSION 563
Front Suspension Oiling 563
Front Suspension Nitrogen Charging 564
REAR SUSPENSION 566
Rear Suspension Oiling 566
Rear Suspension Nitrogen Charging 568
OIL AND NITROGEN SPECIFICATIONS CHART 569
SECTION J BRAKE CIRCUIT 571
SECTION J2 BRAKE CIRCUIT INDEX 573
BRAKE CIRCUIT 575
GENERAL DESCRIPTION 575
SERVICE BRAKE CIRCUIT 575
SECONDARY BRAKING AND AUTOMATIC APPLY 577
PARKING BRAKE CIRCUIT 577
Normal Operation (key switch on, engine on) 577
BRAKE LOCK CIRCUIT 578
WARNING CIRCUIT 578
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 581
BRAKE CIRCUIT COMPONENT SERVICE 583
BRAKE VALVE 583
Rebuild Criteria 583
Removal 583
Installation 585
Disassembly 587
Cleaning and Inspection 589
ASSEMBLY 589
Actuator Base Threaded Inserts 589
Boot and Cap 589
Valve Body Seal Installation 590
Regulator Sleeve O-Ring Installation 591
Actuator Plunger O-Ring Installation 591
Assembly of Valve 591
DIFFERENTIAL PRESSURE SWITCH 592
Disassembly 593
Cleaning and Inspection 593
Assembly 593
VALVE BENCH TEST AND ADJUSTMENT 593
Test Set Up Procedure 595
Brake Valve Output Pressure Adjustment 595
Differential Pressure Switch Test 596
Final Test and Adjustment 596
Installation Of Brake Pedal Actuator Assembly to Brake Valve 597
HYDRAULIC BRAKE ACCUMULATORS 599
Brake Accumulator Bleed-Down Procedure 599
Removal 599
Installation 601
Disassembly 601
Cleaning and Inspection 603
Assembly 603
Leak Testing 606
BRAKE ACCUMULATOR CHARGING 607
Temperature During Precharge 609
ACCUMULATOR STORAGE 609
Installation 610
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 611
BRAKE CIRCUIT CHECK-OUT PROCEDURE 613
EQUIPMENT REQUIRED 616
INITIAL SYSTEM SET-UP 617
Parking Brake 617
Service Brakes 618
Brake Lock/Secondary 618
Low Brake Pressure and Auto Apply 619
Reapplications 619
Differential Pressure Switch 619
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 621
The Brakes are Locked, Service, and/or Parking 621
Both Brake Circuits are Dragging 621
One Brake Circuit is Dragging 621
Brakes are Not Going to Full Pressure 621
A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off 621
Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released 622
Differential Pressure Warning Circuit is Not Operating 622
A Low Brake Pressure Warning Occurs When Brakes are Applied 622
Low Pressure Warning Circuit Not Operating Properly 622
Low Pressure Warning is On Even Though System Pressure is Correct 623
Low Pressure Warning Comes On and Pressure is Low 623
A Squeal is Heard When Controller is Operated 623
Output Pressure At Controller is Correct but Brakes are Not Applying 623
Brake Pressures Drift Excessively While Pedal is Held Steady 623
Oil is Leaking Around the Pedal Base 623
Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM 623
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 624
SECTION J5 FRONT DISC BRAKES INDEX 627
FRONT DISC BRAKES 629
BRAKE CALIPER 629
Removal 629
Installation 630
Disassembly 631
Cleaning and Inspection 631
Assembly 633
BRAKE LINING 633
Replacement 633
FRONT SERVICE BRAKE BURNISHING 635
BRAKE BLEEDING PROCEDURE 636
SECTION J6 REAR BRAKES INDEX 637
REAR DISC BRAKES 639
REAR BRAKES 639
CALIPER, DISC, AND PARKING BRAKE 639
Removal 639
Installation 640
CALIPER PISTON 642
Piston Assembly Removal 642
Inspection 642
Piston Assembly Installation 643
FUNCTIONAL TEST OF PISTON ASSEMBLY 644
Return Spring Force 644
Built-In Clearance 644
Grip Force 646
Grip Force Measurement 647
Spring Force Measurement 649
Disassembly of Piston Assembly 650
Assembly of Piston Assembly 651
BENCH TEST 651
BRAKE LINING 652
Replacement 652
SERVICE BRAKE BURNISHING 655
SAFETY PRECAUTIONS 655
Rear Brake Burnishing 656
BRAKE BLEEDING PROCEDURE 657
Spring Force Measurement 658
SECTION J7 PARKING BRAKE INDEX 659
PARKING BRAKE 661
GENERAL INFORMATION 661
PARKING BRAKE CALIPER 661
Lining Thickness Inspection 661
Removal 662
Installation 662
Parking Brake Adjustment 663
Parking Brake Caliper Disassembly 664
Cleaning and Inspection 665
Parking Brake Caliper Assembly 666
PARKING BRAKE LINING REPLACEMENT 666
PARKING BRAKE BURNISH PROCEDURE 666
Lining Conditioning 666
BRAKE BLEEDING PROCEDURE 667
SECTION L HYDRAULIC SYSTEM 669
SECTION L2 HYDRAULIC SYSTEM INDEX 671
HYDRAULIC SYSTEM 673
GENERAL INFORMATION 673
HYDRAULIC SYSTEMS OPERATION 673
Hoist Circuit Operation 673
Steering Circuit Operation 675
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 679
HYDRAULIC SYSTEM COMPONENT REPAIR 681
HOIST PUMP 681
Removal 681
Installation 682
Disassembly 683
Inspection of Parts 686
Assembly 686
HYDRAULIC TANK 690
Filling Instructions 690
Removal 691
Installation 692
HYDRAULIC TANK STRAINER AND DIFFUSER 693
Removal 693
Inspect and Clean 693
Installation 693
SECTION L4 STEERING CIRCUIT INDEX 695
STEERING CIRCUIT 697
STEERING CIRCUIT OPERATION 697
COMPONENT DESCRIPTION 698
Steering Control Valve 698
Unloader Valve 699
Bleed-Down Manifold Valve 699
Flow Amplifier 704
FLOW AMPLIFIER SYSTEM OPERATION 705
No Steer 705
Steering Left 707
Steering Right 709
No Steer, External Shock Load 711
Steering Pump 713
High Pressure Filter 713
Accumulators 713
Low Precharge Warning Switch 713
SECTION L5 STEERING CONTROL VALVE INDEX 715
STEERING CONTROL VALVE 717
Removal 717
Installation 718
STEERING CONTROL VALVE REBUILD 719
Disassembly 719
Cleaning and Inspection 720
Assembly 720
BRAKE / STEERING PUMP 724
Removal 724
Installation 726
Disassembly 727
Inspection of Parts 727
Assembly 729
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 731
STEERING CIRCUIT COMPONENT REPAIR 733
BLEED-DOWN MANIFOLD 733
Removal 733
Installation 733
ACCUMULATOR 734
Removal 734
Installation 735
Disassembly 736
Cleaning and Inspection 736
Assembly 737
Leak Testing 738
STEERING ACCUMULATOR CHARGING 739
Temperature During Precharge 742
ACCUMULATOR STORAGE 743
Installation 743
FLOW AMPLIFIER 744
Removal 744
Installation 744
Disassembly 745
Assembly 748
STEERING CYLINDERS 749
Disassembly 749
Piston Seal and Bearing Installation 749
Cylinder Assembly 749
Test 749
TROUBLESHOOTING CHART 752
SECTION L7 HOIST CIRCUIT INDEX 757
HOIST CIRCUIT 759
HOIST CIRCUIT OPERATION 759
COMPONENT DESCRIPTION 760
Hydraulic Tank 760
Hydraulic Pump 760
High Pressure Filter 760
Hoist Valve 760
Hoist Pilot Valve 761
Bleed-Down Manifold 762
Counterbalance Manifold 762
Hoist-Up Limit Solenoid 762
Pilot Operated Check Valve 762
HOIST VALVE OPERATION 764
Float Operation 764
Power Up Operation (Figure 7-6) 766
Hold Operation (Figure 7-7) 768
Power Down Operation (Figure 7-8) 770
Float Operation (Figure 7-9) 772
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 775
HOIST VALVE 777
Removal 777
Installation 777
O-Ring Replacement 779
INLET SECTION 780
Disassembly 780
Cleaning and Inspection 781
Assembly 781
REAR SPOOL SECTION (WORK PORTS) 782
Disassembly 782
Cleaning and Inspection 784
Assembly 784
HOIST PILOT VALVE 786
Removal 786
Installation 786
Disassembly 787
Cleaning and Inspection 788
Assembly 788
HOIST UP LIMIT SOLENOID VALVE 789
HOIST CYLINDERS 790
Removal 790
Installation 791
Disassembly 793
Cleaning and Inspection 794
SS1143 Tightening Tool – Assembly Drawing 795
ASSEMBLY OF QUILL AND CYLINDER 795
Quill Installation 795
Installation Of Check Balls And Plugs In Quill 796
Assembly of Cylinder 798
Pressure Testing 799
COUNTERBALANCE MANIFOLD 799
SECTION L9 HIGH PRESSURE FILTERS INDEX 801
HYDRAULIC SYSTEM FILTERS 803
HOIST CIRCUIT FILTER 803
Filter Element Replacement 803
Removal 804
Installation 804
Indicator Switch 804
STEERING CIRCUIT FILTER 805
Filter Element Replacement 805
Removal 806
Installation 806
Indicator Switch 806
INDICATOR SWITCH 806
Test Procedure 806
SECTION L10 HYDRAULIC CHECK-OUT PROCEDURE INDEX 809
HYDRAULIC CHECK-OUT PROCEDURE 811
INITIAL START UP AND FLUSHING 811
COMPONENT CHECKOUT AND ADJUSTMENT 813
ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE 815
Counterbalance Valve Adjustment 817
Manifold Assembly 817
OIL CLEANLINESS CHECK 817
Oil Sampling Location On Truck 817
Oil Sampling Process and Cleanliness Criteria 818
DISABLED TRUCK DUMPING PROCEDURE 818
Hookup 818
Raising the Body 818
Lowering the Body 819
TROUBLESHOOTING CHART 820
Hoist Pump 820
Steering Circuit 822
Brake/Steering Pump 824
Flow Amplifier – Refer to Figure 10-9 826
SECTION M OPTIONS AND SPECIAL TOOLS 827
SECTION M7 HEATER OPTIONS INDEX 829
ENGINE OIL HEATERS 831
GENERAL INFORMATION 831
TROUBLESHOOTING 831
HEATER ELEMENT 832
Removal 832
Installation 832
ENGINE COOLANT HEATER 833
GENERAL 833
Maintenance 833
HEATING ELEMENT 833
Removal 833
Installation 834
THERMOSTAT 834
Removal 834
Installation 834
HYDRAULIC OIL HEATERS 835
GENERAL INFORMATION 835
TROUBLESHOOTING 835
HEATER ELEMENT 836
Removal 836
Installation 836
SECTION M8 SPECIAL TOOLS 837
NITROGEN CHARGING VALVE 837
ROLL-OUT ASSEMBLY 837
EYE BOLT 837
OFFSET WRENCH 838
TORQUE ADAPTER 838
HANDLE 838
SEAL INSTALLER 838
SLEEVE ALIGNMENT TOOLS 839
QUICK DISCONNECT COUPLING 839
HARNESS 839
SEAL INSTALLATION RING 839
BELT TENSION TESTER 840
BELT ALIGNMENT TOOL 840
SOCKETS AND ADAPTERS 840
DUST CAPS 840
HYDRAULIC SYSTEM FLUSHING TOOLS 841
PAYLOAD DATA MANAGER 841
HYDRAULIC SYSTEM VACUUM PUMP 841
MISCELLANEOUS SERVICE TOOLS 842
HIGH VOLTAGE TOOLS 845
2000 VDC METER 845
GROUNDING STICKS 845
BODY PAD SPACER TOOL 846
SECTION M19 RADIATOR SHUTTERS INDEX 847
RADIATOR SHUTTERS 849
OPERATION 849
Hydraulic Circuit 849
Electrical Circuit: 850
MAINTENANCE AND REPAIR 850
TROUBLESHOOTING 851
Hydraulic Troubleshooting 854
Electrical Troubleshooting 856
SECTION N OPERATOR’S CAB 857
SECTION N2 TRUCK CAB INDEX 859
TRUCK CAB 861
TRUCK CAB 861
Description 861
Removal 862
Installation 864
CAB DOOR 864
Removal 864
Installation 865
Door Adjustment 865
Door Jam Bolt Adjustment 865
Door Handle Plunger Adjustment 867
Replace Door Glass 868
Replace Door Window Regulator 872
Replace Door Handle or Latch Assembly 872
Door and Door Hinge Seal Replacement 873
Door Opening Seal Removal 873
Installation 873
GLASS REPLACEMENT 874
Adhesive-Bonded Windows 874
Recommended Tools/Supplies 874
Replacement Procedure 874
Windshield and Rear Glass 875
Removal 875
Installation 876
REMOVAL AND INSTALLATION OF OPERATOR SEAT 877
Inspection 877
Removal 877
Installation 877
REMOVAL AND INSTALLATION OF PASSENGER SEAT 878
Removal 878
Installation 878
SECTION N3 CAB COMPONENTS INDEX 879
WINDSHIELD WIPERS 881
WIPER MOTOR REPLACEMENT 881
Removal 881
Installation 881
WIPER ARM REPLACEMENT 881
Removal 881
Installation 882
WIPER LINKAGE REPLACEMENT 882
Removal 882
Installation 883
WINDSHIELD WASHER 883
Operation 883
Service 883
SEAT BELT 884
Removal 884
Installation 884
SECTION N4 OPERATOR COMFORT INDEX 887
OPERATOR COMFORT 889
HEATER / AIR CONDITIONER 889
Fan Speed Control Knob 889
Temperature Control Knob 889
Air Flow Directional Knob 889
Heater/Air Conditioner Vents 890
COMPONENTS 890
Fuse and Circuit Breaker 890
Relays 890
Heater Core 890
Fan Motor And Speed Control 891
Actuators 891
Cab Air Filter 891
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 894
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 894
PRINCIPLES OF REFRIGERATION 894
Air Conditioning 894
Refrigeration – The Act Of Cooling 895
The Refrigeration Cycle 895
AIR CONDITIONER SYSTEM COMPONENTS 896
Compressor (Refrigerant Pump) 896
Service Valves 896
Condenser 896
Receiver-Drier 896
Expansion Block Valve 897
Accumulator 897
Evaporator 897
ELECTRICAL CIRCUIT 898
Thermostat 898
Compressor Clutch 898
Trinary™ Switch 899
SYSTEM SERVICING 900
SERVICE TOOLS AND EQUIPMENT 901
Recovery/Recycle Station 901
Leak Detector 901
Service Valves 902
Vacuum Pump 902
Manifold Gauge Set 903
Installing Manifold Gauge Set 904
Purging Air From Service Hoses 904
SYSTEM PERFORMANCE TEST 905
SYSTEM OIL 906
Handling and Reusing PAG Oil 906
Oil Quantity 906
Checking System Oil 906
REFRIGERANT 907
Recycled Refrigerant 907
Reclaimed Refrigerant 907
Refrigerant Quantity 907
R-134a Refrigerant Containers 908
SYSTEM LEAK TESTING 908
Electronic Leak Detector 909
Tracer Dyes 909
Soap and Water 909
RECOVERING AND RECYCLING THE REFRIGERANT 909
Draining Oil from the Previous Recovery Cycle 909
Performing the Recovery Cycle 909
Performing the Recycling Procedure 910
Evacuating and Charging the A/C System 910
SYSTEM REPAIR 910
System Flushing 910
A/C DRIVE BELT CHECKOUT PROCEDURE 911
Pulley Alignment 911
Belt Tension Check 911
COMPONENT REPLACEMENT 913
Hoses and Fittings 913
Lines 913
Expansion Valve 913
Receiver-Drier 913
Thermostat 913
Compressor 914
Accumulator 914
Clutch 914
Servicing the Compressor Clutch 915
Pulley Removal 917
Clutch Coil Check 918
Pulley Installation 918
Clutch Assembly Installation 918
EVACUATING THE SYSTEM 920
CHARGING THE A/C SYSTEM 922
TROUBLESHOOTING 923
Preliminary Checks 923
Diagnosis Of Gauge Readings And System Performance 923
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 924
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 930
SECTION N5 OPERATOR CONTROLS AND EQUIPMENT INDEX 931
STEERING WHEEL AND CONTROLS 934
HORN BUTTON 934
TILT/TELESCOPE LEVER 934
M ULTI-FUNCTION TURN SIGNAL SWITCH 934
Turn Signal Operation 934
High Beam Headlight Operation 934
Windshield Wiper Operation 934
STEERING COLUMN 935
Removal 935
Inspection 935
Installation 936
STEERING WHEEL 936
Removal 936
Installation 936
PEDALS 938
SERVICE BRAKE PEDAL 938
DYNAMIC RETARDER PEDAL 938
Optional – Dual Function/Single Pedal 938
THROTTLE PEDAL 938
GRADE/SPEED WARNING CHART 939
OVERHEAD PANEL CONTROLS AND COMPONENTS 939
RADIO SPEAKERS 939
WARNING ALARM BUZZER 939
CAB RADIO 939
WARNING LIGHTS DIMMER CONTROL 939
WARNING/STATUS INDICATOR LIGHT PANEL 939
AIR CLEANER VACUUM GAUGES 939
WINDSHIELD WIPERS 939
TRUCK CONTROLS 940
F-N-R Selector Switch 940
Hoist Control Lever 941
CONSOLE SWITCHES AND CONTROLS 941
Ashtray 941
Cigarette Lighter 941
Left-Hand Window Control Switch 941
Right-Hand Window Control Switch 941
Engine Shutdown Switch 941
Override Switch 941
Retard Speed Control (RSC) Switch 942
Retard Speed Control (RSC) Dial 942
Statex III Download Port 943
Engine Diagnostic Port (CENSE) 943
Passenger Seat 943
Engine Diagnostic Connectors 943
Engine Diagnostics Connector 943
Modular Mining Port 943
Data Store Button 943
PAYLOAD METER 943
Payload Meter Download Connector 943
OPERATOR’S SEAT 944
Seat Belts 944
Adjustment 944
INSTRUMENT PANEL 945
CONTROL SYMBOLS 945
CONTROL SWITCHES AND GAUGES 946
Key Switch 946
Engine Shutdown Switch With Timer Delay 947
Fog Light Switch 947
Ladder Light Switch 947
Backup Light Switch 947
Panel Illumination Lights 947
Cab Air Conditioner/Heater Vents 947
Engine Cold Weather Starting Aid Switch 947
Rotating Beacon Light Switch 947
Heated Mirror Switch 947
Leakage Test Switch (Trolley Option Only) 947
Wheel Brake Lock Switch 948
Parking Brake Switch 948
Digital Tachometer 948
Right Turn Signal Indicator Light 949
High Beam Headlight Indicator Light 949
Left Turn Signal Indicator Light 949
Digital Speedometer/Payload Meter Display 949
Voltmeter Gauge 949
Engine Oil Pressure Gauge 949
Engine Water Temperature Gauge 949
Fuel Gauge 949
Engine Hourmeter 949
Headlight Switch 950
Panel Illumination Lights Dimmer Rheostat 950
Payload Meter Switch 950
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL 951
DESCRIPTION OF INDICATOR SYMBOLS 951
INDICATOR LIGHT FUNCTIONS 952
A1 High Hydraulic Oil Temperature 952
B1 Low Steering Pressure 952
C1 Low Accumulator Precharge Pressure 953
D1 Electric System Fault 953
E1 Low Brake Pressure 953
A2 Low Hydraulic Tank Level 953
B2 Automatic Lubrication System Pressure 953
C2 Circuit Breaker Tripped 953
D2 Hydraulic Oil Filter Monitor 954
E2 Low Fuel 954
A3 Parking Brake 954
B3 Service Brake 954
C3 Body Up 954
D3 Dynamic Retarding 954
E3 Stop Engine 954
A4 Not Used 955
B4 Manual Backup Lights 955
C4 Engine Shutdown Timer 955
D4 Retard Speed Control (RSC) 955
E4 Check Engine 955
A5 Service Engine Indicator (AEM) 955
B5 High Wheel Motor Temperature 955
C5 Blower Fault 955
A4, D5, E5, A6, B6, C6, D6, and E6 Not Used 955
D6 Service Engine (CENSE) 955
E6 Not Used 955
Komatsu Engines w/Centry™ Fuel Control 956
Hazard Warning Light Switch 956
Lamp Test Switch/Centry™ Diagnostic Test Switch 956
REAR AXLE LIGHT BAR 957
Backup Lights 957
Retard Lights 957
Brake Light 957
Backup Alarm 957
KOMTRAX Plus 958
Operation 958
Interface Module 960
Basic Precautions 960
CENTRY™ FUEL SYSTEM DIAGNOSTICS 961
GENERAL OPERATION 961
DETERMINING FAULT CODES 961
EXITING THE DIAGNOSTICS MODE 962
SECTION P LUBRICATION AND SERVICE 963
SECTION P2 LUBRICATION AND SERVICE INDEX 965
LUBRICATION AND SERVICE 967
GENERAL INFORMATION 967
HYDRAULIC TANK SERVICE 967
Adding Oil 967
COOLANT LEVEL CHECK 968
Radiator Filling Procedure 968
Coolant Specifications 968
Unacceptable Practices 968
WHEEL MOTOR SERVICE 968
RESERVE ENGINE OIL SYSTEM (Optional) 969
Reserve Oil Tank Filling Procedure (Remote fill) 969
Inline Screen 969
QUICK FILL SERVICE CENTER 970
LUBRICATION CHART 971
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS 972
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued) 973
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 974
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 974
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 975
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 976
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 977
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 978
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 979
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS 980
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS 980
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 981
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS 982
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 983
AUTOMATIC LUBRICATION SYSTEM 985
GENERAL DESCRIPTION 985
SYSTEM COMPONENTS 986
Filter Assembly 986
Hydraulic Motor and Grease Pump 986
Reservoir 986
Fixed Pressure Reducing Valve 986
Flow Control Valve 986
Solenoid Valve 987
Vent Valve 987
24VDC Lubrication Cycle Timer 987
Time Delay Module 987
Pump Cutoff Pressure Switch 987
Unloader Valve 987
Pressure Switch 987
Manual Override Button 987
Injectors 987
SYSTEM OPERATION 990
Normal Operation 990
Pressure Failure Detection Circuits 991
GENERAL INSTRUCTIONS 992
LUBRICANT REQUIRED FOR SYSTEM 992
SYSTEM PRIMING 992
LUBRICANT PUMP 993
Pump Housing Oil Level 993
Pump Pressure Control 993
FILTER AND RESERVOIR 993
Filter Assembly Element 994
INJECTORS (SL-1 Series H) 994
Injector Specifications 994
Injector Adjustment 994
INJECTOR OPERATION 996
SYSTEM CHECKOUT 997
Lubrication Cycle Timer Check 997
Lubrication Cycle Timer Adjustment 998
PREVENTIVE MAINTENANCE INSPECTION 998
10 Hour Lubrication System Inspection 998
100 Hour Inspection 998
250 Hour Inspection 998
500 Hour Inspection 999
1000 Hour Inspection 999
PUMP REBUILD 1000
Disassembly 1000
Cleaning and Inspection 1000
Assembly 1002
VENT VALVE REBUILD 1003
Disassembly and Assembly 1003
SYSTEM TROUBLESHOOTING CHART 1004
SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX 1007
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1009
AXLE BOX 1009
ARMATURE AREA 1010
AT TIRE CHANGE 1010
GENERATOR/ALTERNATOR 1011
GRID BLOWER MOTOR 1011
CONTROL EQUIPMENT CHECKS 1011
VEHICLE OPERATIONS TESTS 1012
SECTION R SYSTEM SCHEMATICS 1013
HYDRAULIC BRAKE SYSTEM SCHEMATIC – EF5755 1014
HYDRAULIC SYSTEM SCHEMATIC – EJ2729 1015
VHMS SYSTEM SCHEMATIC – EL8720 1016
HVAC WIRING SCHEMATIC – HE484 1021
ELECTRICAL SCHEMATIC – XS8600 1022

DESCRIPTION:

Komatsu 730E DUMP TRUCK Shop Manual CEBM026501  – PDF DOWNLOAD

• SERIAL NUMBERS 730E A30633 and up

• 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 requirements 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.
• 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.
• Exceeding the allowable payload will reduce the expected life of truck components.

G.B 20/12/24