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Komatsu 730E Dump Truck Shop Manual SN A30633 & UP – PDF DOWNLOAD
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Komatsu 730E Dump Truck Shop Manual
Book Code: CEBM026500
SERIAL NUMBERS A30633 & UP
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Description
Komatsu 730E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 730E Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 730E
Serial Number: A30633 & UP
Book Code: CEBM026500
Language: English
Pages: 1054
File Format: Portable Document Format (PDF)
KOMATSU 730E DUMP TRUCK SHOP MANUAL SN A30633 & UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 730E Dump Truck Shop Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, wamings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general infom’ration. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only 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 of US. and metric (SI) units throughout and all references to “Right”, “Left”.
- ‘Front‘, or “Rear” are made with respect to the operator’s nomtal seated position, unless specifically stated otherwise- Standard torque requirements are shown in torque charts in the general infomiation section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 Mm) torque- All torque specifications have i 10% tolerance unless otherwise specified.
- A Product identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (i.e. 730E). The three numbers represent the basic truck model. The letter ‘M’ designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains infomiation which will identify the original manufacturing bill of material forthis unit. This complete number will be necessary for proper ordering of many service parts andlor warranty consideration.
TABLE OF CONTENTS:
Komatsu 730E Dump Truck Shop Manual
COVER ..................................................................................................... 1 FOREWORD................................................................................................... 5 TABLE OF CONTENTS.......................................................................................... 7 SECTION A GENERAL INFORMATION INDEX........................................................................ 9 SECTION A2 SPECIFICATIONS............................................................................. 13 Komatsu SSA16V159.................................................................................. 13 SECTION A3 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 SECTION A5 TORQUE TABLES AND CONVERSION CHARTS ........................................................ 59 SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX.................................................. 69 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 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 INDEX..................................................................................... 115 SECTION C2 POWER MODULE INDEX.......................................................................... 117 POWER MODULE....................................................................................... 119 GENERAL INFORMATION............................................................................ 119 POWER MODULE SERVICE........................................................................... 120 Removal.................................................................................... 120 Installation............................................................................... 124 SECTION C3 COOLING SYSTEM INDEX........................................................................ 127 COOLING SYSTEM..................................................................................... 129 RADIATOR....................................................................................... 129 Removal.................................................................................... 129 Service.................................................................................... 130 Installation............................................................................... 130 RADIATOR FILL PROCEDURE........................................................................ 131 RADIATOR REPAIR................................................................................ 131 Internal Inspection........................................................................ 131 External Cleaning.......................................................................... 132 Disassembly................................................................................ 132 Cleaning and Inspection.................................................................... 133 Assembly................................................................................... 133 Additional Service Information............................................................. 135 PRESSURE TESTING............................................................................... 135 COOLANT SYSTEM TROUBLESHOOTING................................................................. 135 SECTION C4 POWER TRAIN INDEX........................................................................... 137 POWER TRAIN........................................................................................ 139 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.................................................. 139 General Information........................................................................ 139 Removal.................................................................................... 139 ALTERNATOR INSTALLATION........................................................................ 141 Engine/Alternator Mating................................................................... 141 Alternator Measurement..................................................................... 141 Engine End Play Measurement................................................................ 142 Determining Shim Requirements.............................................................. 143 Installing Alternator On Engine............................................................ 144 ENGINE......................................................................................... 145 Removal.................................................................................... 145 Installation............................................................................... 145 SECTION C5 AIR CLEANERS INDEX.......................................................................... 147 OPERATION.......................................................................................... 149 SERVICING THE AIR CLEANERS......................................................................... 149 Replacing The Elements......................................................................... 150 AIR CLEANER ASSEMBLY CLEANING...................................................................... 151 Primary Element Cleaning....................................................................... 151 Precleaner Section Cleaning.................................................................... 153 AIR INTAKE TROUBLESHOOTING......................................................................... 154 SECTION C7 FAN DRIVE CLUTCH INDEX...................................................................... 155 COMPONENTS......................................................................................... 156 Input.......................................................................................... 156 Output......................................................................................... 156 Stationary Components.......................................................................... 157 OPERATIONAL MODES.................................................................................. 158 Fully Engaged.................................................................................. 158 Modulated Variable Speed....................................................................... 158 Fully Released................................................................................. 159 Lubricating and Cooling Oil.................................................................... 160 MAINTENANCE........................................................................................ 161 TROUBLESHOOTING.................................................................................... 162 Preliminary Checks............................................................................. 162 FIELD CHECK DIAGNOSIS.............................................................................. 163 Preliminary Checks - Engine Off................................................................ 163 Check Clutch Release........................................................................... 163 Check Clutch Lock-up........................................................................... 164 Overheating.................................................................................... 164 Thermal Sensor and Solenoid Valve.............................................................. 165 On Truck Test.................................................................................. 165 Off Truck Test................................................................................. 165 FAN CLUTCH DISASSEMBLY INSTRUCTIONS................................................................ 170 REASSEMBLY OF THE FAN CLUTCH....................................................................... 177 INSPECTION OF PARTS................................................................................ 188 REBUILD TOOLS...................................................................................... 192 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX................................................... 193 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX.......................................................... 195 ELECTRICAL SYSTEM DESCRIPTION...................................................................... 197 BATTERIES.......................................................................................... 197 Maintenance and Service........................................................................ 197 Troubleshooting................................................................................ 197 BATTERY CHARGING ALTERNATOR........................................................................ 199 24VDC ELECTRIC START SYSTEM........................................................................ 199 CRANKING MOTORS................................................................................ 199 Removal.................................................................................... 199 Installation............................................................................... 200 CRANKING MOTOR TROUBLESHOOTING................................................................. 200 Preliminary Inspection..................................................................... 201 No-Load Test............................................................................... 201 Interpreting Results of Tests.............................................................. 201 Disassembly................................................................................ 202 Cleaning and Inspection.................................................................... 202 Armature Servicing......................................................................... 203 Field Coil Checks.......................................................................... 205 Field Coil Removal......................................................................... 205 Solenoid Checks............................................................................ 205 Test....................................................................................... 205 Assembly................................................................................... 207 Pinion Clearance........................................................................... 208 MAGNETIC SWITCH................................................................................ 208 Coil Test.................................................................................. 208 Electric Start System Wiring Diagrams...................................................... 208 ENGINE PRELUB SYSTEM............................................................................... 209 OPERATION...................................................................................... 209 Pressure Switch............................................................................ 209 Suction Line............................................................................... 209 Outlet Line................................................................................ 209 Check Valve................................................................................ 209 Solenoid Timer............................................................................. 209 TROUBLESHOOTING PRELUB STARTER CIRCUIT............................................................. 211 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX.................................................... 215 PASSENGER SEAT BASE COMPARTMENT.................................................................... 217 COMPONENTS......................................................................................... 217 Taillight Resistor Diode Assemblies............................................................ 217 Inclinometer................................................................................... 217 Lubrication System Timer....................................................................... 217 Three Minute Idle Timer Components............................................................. 217 Three Minute Idle Timer........................................................................ 219 Idle Timer Relay............................................................................... 219 Three Minute Idle Contactor.................................................................... 219 Three Minute Idle Circuit Test................................................................. 219 Data Store Button.............................................................................. 219 Komatsu Engine Diagnostic Connector (Centry)................................................... 219 Komatsu Engine Diagnostic Port (CENSE)......................................................... 219 STATEX III Propulsion System Diagnostic Connector.............................................. 219 Alarm Indicating Device (AID) System........................................................... 220 Diode Matrix (Without Sound)................................................................... 220 Diode Matrix (With Sound)...................................................................... 221 Hot Switch Inverter............................................................................ 221 Hot Switch Inverter Card (Slot 4) (Not Used)................................................... 221 Temperature.................................................................................... 221 Oil Level...................................................................................... 221 Temperature and Latch.......................................................................... 221 Coolant Level/Flasher.......................................................................... 222 Lamp Test...................................................................................... 222 BATTERY EQUALIZER BOX.............................................................................. 222 Troubleshooting................................................................................ 222 BODY POSITION SWITCHES............................................................................. 224 Proximity Switch Operation..................................................................... 224 Body-Up Switch Adjustment...................................................................... 225 Hoist Limit Switch Adjustment.................................................................. 225 24-VOLT RELAY AND DIODE BOARDS..................................................................... 227 RELAY BOARDS....................................................................................... 228 Description.................................................................................... 228 SERVICE............................................................................................ 228 To Replace A Relay:............................................................................ 228 To Replace A Circuit Breaker:.................................................................. 228 To Replace A Circuit Panel Card................................................................ 229 Relay Board Components......................................................................... 229 Installing Additional Circuits................................................................. 230 DIODE BOARD 1.................................................................................. 231 Diode Testing.................................................................................. 231 CIRCUIT BREAKERS................................................................................... 233 SECTION D11 KOMTRAX Plus COMPONENTS INDEX.............................................................. 235 VEHICLE HEALTH MONITORING SYSTEM (KOMTRAX Plus).................................................... 237 KOMTRAX Plus BASIC FEATURES.................................................................... 237 Gather Data................................................................................ 237 Convert and Record Data.................................................................... 238 Communicate Data to Off-Board Systems...................................................... 238 USING THE KOMTRAX Plus SYSTEM.................................................................. 239 Basic Precautions.......................................................................... 239 Turning the KOMTRAX Plus System On......................................................... 239 Normal KOMTRAX Plus Operation.............................................................. 240 Turning the KOMTRAX Plus System Off........................................................ 240 Downloading From the KOMTRAX Plus Controller............................................... 240 KOMTRAX Plus DATA ITEMS........................................................................ 241 Fault Codes................................................................................ 241 Machine History............................................................................ 241 KOMTRAX Plus History....................................................................... 242 Snapshots.................................................................................. 242 Manual Snapshots........................................................................... 242 Trends..................................................................................... 242 Histogram (Load Map) Data.................................................................. 244 Haul Cycle Data............................................................................ 245 Alarm and Snapshot Triggers................................................................ 246 Satellite Features......................................................................... 248 KOMTRAX Plus DIAGNOSTIC FEATURES............................................................... 248 Fault History.............................................................................. 248 KOMTRAX Plus LED Digits.................................................................... 248 Light (10) PLM III communication........................................................... 248 Light (11) OrbComm......................................................................... 248 KOMTRAX Plus COMPONENTS............................................................................ 249 KOMTRAX Plus CONTROLLER........................................................................ 249 Removal.................................................................................... 250 Installation............................................................................... 250 OrbComm Controller......................................................................... 251 Removal.................................................................................... 251 Installation............................................................................... 252 INTERFACE MODULE............................................................................... 252 Inputs..................................................................................... 253 Outputs.................................................................................... 253 Removal.................................................................................... 253 Installation............................................................................... 253 COMPONENT LOCATION............................................................................. 254 Circuit Breakers........................................................................... 254 Temperature Sensors........................................................................ 255 Pressure Sensors........................................................................... 256 KOMTRAX Plus SOFTWARE.............................................................................. 259 Necessary Software............................................................................. 259 Necessary Tools................................................................................ 260 KOMTRAX Plus TOOL BOX INSTALLATION............................................................. 260 KOMTRAX Plus SETTING TOOL INSTALLATION......................................................... 261 KOMTRAX Plus INITIALIZATION PROCEDURE.......................................................... 261 Preliminary Checks......................................................................... 261 Initialization Steps....................................................................... 261 Select Operation........................................................................... 262 KOMTRAX Plus Setting Function.............................................................. 262 Machine Information Setting(1)............................................................. 262 Machine Information Setting(2)............................................................. 262 Date and Time Setting...................................................................... 263 GCC Setting................................................................................ 263 Setting Summary............................................................................ 263 KOMTRAX Plus SNAPSHOT PROCEDURE................................................................ 264 KOMTRAX Plus DOWNLOAD.......................................................................... 264 KOMTRAX Plus FTP UPLOAD........................................................................ 265 LOCATION OF DOWNLOAD FILES..................................................................... 266 INSTALLING FLASHBURN PROGRAM................................................................... 267 INSTALLING APPLICATION CODE INTO INTERFACE MODULE.............................................. 267 INSTALLING REALTIME MONITOR SOFTWARE PROGRAM................................................... 268 WHEN REPLACING A KOMTRAX Plus CONTROLLER....................................................... 268 To Set: Date and time, satellite, payload meter............................................ 270 Review Setting Information................................................................. 272 SECTION D12 KOMTRAX Plus SOFTWARE INDEX................................................................ 257 SECTION D13 KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING INDEX............................................ 273 KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING.......................................................... 276 KOMTRAX Plus CHECKOUT PROCEDURE................................................................ 276 General.................................................................................... 276 Structure and Purpose...................................................................... 277 Necessary Equipment:....................................................................... 277 KOMTRAX Plus SYSTEM CHECKOUT................................................................... 277 Preliminary................................................................................ 277 Checking Inputs To The Interface Module.................................................... 278 For 930E & 960E trucks only:............................................................... 280 For 830E trucks only:...................................................................... 280 Checking Outputs From The Interface Module................................................. 281 For 830E only:............................................................................. 281 For 930E & 960E only:...................................................................... 281 KOMTRAX Plus CONTROLLER CHECKOUT............................................................... 281 TROUBLESHOOTING................................................................................ 282 Communications Networks.................................................................... 282 Coaxial Cable.............................................................................. 282 KOMTRAX Plus COMPONENTS........................................................................ 283 KOMTRAX Plus Controller.................................................................... 283 OrbComm Controller......................................................................... 284 Interface Module........................................................................... 284 FAULT CODES.................................................................................... 285 Fault History.............................................................................. 285 KOMTRAX Plus LED Display Fault Codes....................................................... 286 Chassis Fault Codes........................................................................ 287 Engine Fault Codes......................................................................... 291 FAULT TREE ANALYSIS............................................................................ 297 Unable to connect to KOMTRAX Plus from laptop PC........................................... 297 Flashing Error Code N4-23 (PLM III Communications Fault)................................... 298 Flashing Error Code N4-22 (Engine Communications Fault).................................... 299 No Data Received By WebCARE................................................................ 300 Coaxial Cable Troubleshooting.............................................................. 301 SECTION D14 KOMTRAX PLUS FORMS INDEX................................................................... 303 KOMTRAX PLUS FORMS................................................................................. 305 KOMTRAX PLUS INITIALIZATION CHECK LIST......................................................... 305 KOMTRAX PLUS DATA DOWNLOAD..................................................................... 306 KOMTRAX PLUS INITIALIZATION CHECK LIST......................................................... 307 KOMTRAX PLUS INITIALIZATION FORM............................................................... 309 SECTION D35 PAYLOAD METER III INDEX.................................................................... 311 Introduction....................................................................................... 316 Data Summary................................................................................... 316 Data Gathering................................................................................. 316 COMPONENT DESCRIPTION.............................................................................. 317 System Diagram................................................................................. 317 Suspension Pressure Sensors.................................................................... 317 Inclinometer................................................................................... 317 Operator Display............................................................................... 317 Operator Switch................................................................................ 318 Speed Input.................................................................................... 318 Body-Up Switch................................................................................. 318 Brake Lock Switch.............................................................................. 318 Payload Meter.................................................................................. 318 Communications Ports........................................................................... 318 Key Switch Input............................................................................... 319 Payload Meter Power............................................................................ 319 Load Lights.................................................................................... 319 Wiring and Termination......................................................................... 320 TCI Outputs.................................................................................... 320 OPERATOR’S DISPLAY AND SWITCH...................................................................... 321 Reading the Speedometer........................................................................ 321 Reading the Load Display....................................................................... 321 Using the Operator ID.......................................................................... 321 Using the Load and Ton Counter................................................................. 321 Total Ton Counter.............................................................................. 321 Total Load Counter............................................................................. 322 Clearing the Counters.......................................................................... 322 Viewing Live Sensor Data....................................................................... 322 Other Display Messages......................................................................... 322 PAYLOAD OPERATION & CALCULATION.................................................................... 323 Description of Haul Cycle States............................................................... 323 Haul Cycle Description......................................................................... 323 Load Calculation............................................................................... 324 Carry Back..................................................................................... 324 Measurement Accuracy........................................................................... 324 SOURCES FOR PAYLOAD ERROR.......................................................................... 324 Payload Error.................................................................................. 324 Loading Conditions............................................................................. 325 Pressure Sensors............................................................................... 325 Swingloads..................................................................................... 325 Speed and Distance............................................................................. 325 HAUL CYCLE DATA.................................................................................... 325 Haul Cycle Warning Flags....................................................................... 327 Frame Torque Data.............................................................................. 328 Sprung Weight Data............................................................................. 328 Maximum Speed Data............................................................................. 328 Alarm Records.................................................................................. 328 Fault Code Data................................................................................ 329 PC SOFTWARE OVERVIEW............................................................................... 330 System Configuration........................................................................... 330 Installing the PLMIII Software................................................................. 330 DOWNLOADING DATA................................................................................... 331 PLM III SYSTEM CONFIGURATION....................................................................... 332 Starting Communications........................................................................ 332 Displayed Payload Units........................................................................ 332 Time Units..................................................................................... 332 Connection Menu................................................................................ 332 Connecting to the Payload Meter................................................................ 333 Configure the Payload Meter.................................................................... 333 Setting the Date and Time...................................................................... 333 Setting the Truck Type......................................................................... 334 Setting the Gauge Display Units................................................................ 334 Setting the Frame Serial Number................................................................ 334 Setting the Truck Number....................................................................... 334 Setting the Komatsu Distributor................................................................ 334 Setting the Komatsu Customer................................................................... 334 Setting the Overload Speed Limit Function...................................................... 335 Clean Truck Tare............................................................................... 336 Inclinometer Calibration....................................................................... 336 DATA ANALYSIS...................................................................................... 337 Creating a Query............................................................................... 337 Sorting on Truck Unit Number................................................................... 337 Sorting on Truck Type.......................................................................... 337 Sorting on Date Range.......................................................................... 338 Sorting on Time Range.......................................................................... 338 Payload Detail Screen.......................................................................... 339 Creating Reports............................................................................... 339 Summary - one page report...................................................................... 340 Detailed - multi-page report................................................................... 340 Creating Graphs................................................................................ 341 Exporting Data................................................................................. 341 CSV Export..................................................................................... 341 Compressed..................................................................................... 342 Importing Data................................................................................. 343 Deleting Haul Cycle Records.................................................................... 343 Viewing Alarms................................................................................. 344 Deleting Alarm Records......................................................................... 344 TROUBLESHOOTING SECTION............................................................................ 345 TROUBLESHOOTING................................................................................ 345 Viewing Active Alarms...................................................................... 345 Real-Time Data Display..................................................................... 345 Testing the Payload Lights................................................................. 345 Creating Log Files of Inputs............................................................... 346 Daily Inspections.......................................................................... 346 Periodic Maintenance....................................................................... 346 Abnormal Displays at Power-Up.............................................................. 347 No Payload Display When Key Switch is Turned ON............................................ 348 No Display on Speedometer.................................................................. 349 No Display on Operator Display............................................................. 349 No Communications With PC.................................................................. 350 Load Lights Don’t Light During Loading..................................................... 351 Load Lights Remain ON...................................................................... 352 Load Lights Remain ON During Dumping....................................................... 352 Display Doesn't Clear When The Load Is Dumped.............................................. 352 Calibration Problems....................................................................... 353 Alarm 1 - Left Front Pressure High......................................................... 354 Alarm 2 - Left Front Pressure Low.......................................................... 354 Troubleshoot Wiring to Left Front Suspension............................................... 354 Alarm 3 - Right Front Pressure High........................................................ 355 Alarm 4 - Right Front Pressure Low......................................................... 355 Troubleshoot Wiring to Right Front Suspension.............................................. 355 Alarm 5 -Left Rear Pressure High........................................................... 356 Alarm 6 - Left Rear Pressure Low........................................................... 356 Troubleshoot Wiring to Left Rear Suspension................................................ 356 Alarm 7 - Right Rear Pressure High......................................................... 357 Alarm 8 - Right Rear Pressure Low.......................................................... 357 Troubleshoot Wiring to Right Rear Suspension............................................... 357 Alarm 9 - Inclinometer High................................................................ 358 Alarm 10 - Inclinometer Low................................................................ 358 Troubleshoot Inclinometer Wiring........................................................... 358 Alarm 13 - Body Up Input Failure........................................................... 359 Alarm 16 - Memory Write Failure............................................................ 360 Alarm 17 - Memory Read Failure............................................................. 360 Alarm 18................................................................................... 360 Alarm 19................................................................................... 360 Alarm 22................................................................................... 360 Operator Switch Doesn't Work............................................................... 361 Alarm 26 - User Switch Fault - SELECT...................................................... 361 Alarm 27 - User Switch Fault - SET......................................................... 361 Connector Map.............................................................................. 362 Connectors................................................................................. 363 General Description........................................................................ 364 Tools Required............................................................................. 364 Checkout Procedure......................................................................... 364 PLMIII CHECKOUT PROCEDURE CONFIRMATION......................................................... 368 Flashburn Programming...................................................................... 368 Confirmation Checklist..................................................................... 370 SECTION E ELECTRICAL PROPULSION INDEX...................................................................... 371 SECTION E2 ELECTRICAL PROPULSION COMPONENTS INDEX...................................................... 373 GENERAL SYSTEM DESCRIPTION......................................................................... 377 CONTROL SYSTEM..................................................................................... 377 System Operation............................................................................... 378 FL275 Panel.................................................................................... 379 CARD REPLACEMENT................................................................................... 380 Removal........................................................................................ 380 Installation................................................................................... 380 Card Repair.................................................................................... 380 Panel Wiring................................................................................... 380 COMPUTER DESCRIPTION............................................................................... 381 Microprocessor................................................................................. 381 Download Capability............................................................................ 381 SOFTWARE........................................................................................... 381 Base Monitor Program........................................................................... 381 Runtime Monitor Program - OBJ Running Code..................................................... 381 Configuration Software - CFG................................................................... 382 PTU - Portable Test Unit Code.................................................................. 382 System Regulation.............................................................................. 382 Propulsion..................................................................................... 383 Retarding...................................................................................... 383 TWO-DIGIT DISPLAY PANEL............................................................................ 384 The Coded Number............................................................................... 384 Events......................................................................................... 384 Frames......................................................................................... 385 Windows........................................................................................ 385 System Categories.............................................................................. 385 Limits On Resetting Faults..................................................................... 385 NA Faults...................................................................................... 386 Event Sequence................................................................................. 386 Resetting Events............................................................................... 386 Event Descriptions............................................................................. 386 Subcode Descriptions........................................................................... 386 PORTABLE TEST UNIT (PTU)........................................................................... 397 DESCRIPTION.................................................................................... 397 Operational Hints.......................................................................... 397 SOFTWARE INSTALLATION PREPARATION.............................................................. 398 HARD DISK SPACE REQUIREMENTS................................................................... 398 SOFTWARE INSTALLATION ON PTU................................................................... 398 PTU/Truck Communication Problems........................................................... 399 THE MAIN MENU.................................................................................. 400 Quit Menu.................................................................................. 400 PTU Talk To Truck.......................................................................... 400 View PTU Saved Files....................................................................... 400 List Stat Data Files....................................................................... 400 Truck Setup (CFG).......................................................................... 400 Select Truck Setup......................................................................... 400 Update CFG Version......................................................................... 400 Change PTU Password........................................................................ 400 CONFIGURATION (CFG) FILE CONVERSION............................................................ 402 Conversion Procedure....................................................................... 402 Convert Old CFG files for New software..................................................... 403 STATEX CONFIGURATION FILES..................................................................... 406 0) Source Directory: . . .................................................................. 406 1) Select A Truck Configuration . . ....................................................... 407 2) View Truck Configuration: Data Curves . . .............................................. 408 3) Change/View Serial and Model Numbers . . ............................................... 409 4) View Options . . ....................................................................... 409 5) Change/View Truck Specifics . . ........................................................ 411 6) Change/View Overspeeds . . ............................................................. 413 7) Save a Truck Configuration, filename: . . .............................................. 414 8) Save Directory: . . .................................................................... 415 CHANGE PTU PASSWORD............................................................................ 416 PROGRAMMING THE TRUCK.......................................................................... 417 Connect PTU to the Truck................................................................... 417 Select Configuration File.................................................................. 417 Activate The PTU Mode...................................................................... 417 Check Object Code Version.................................................................. 418 Download Configuration Files............................................................... 419 Date And Time.............................................................................. 420 Event Data................................................................................. 421 Statistical Data........................................................................... 423 View Counters.............................................................................. 423 View Profiles.............................................................................. 423 Upload Statistical Data To A File.......................................................... 423 Statistical Data Codes - Counters.......................................................... 424 STATISTICAL DATA CODES - COUNTERS.............................................................. 425 STATISTICAL DATA CODES - PROFILES.............................................................. 430 TRUCK SPECIFIC INFORMATION..................................................................... 434 Temporary Truck Settings................................................................... 435 MISCELLANEOUS FEATURES......................................................................... 436 Saving Data................................................................................ 436 PTU Abbreviations.......................................................................... 437 Other Menu Selections...................................................................... 437 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..................................................... 438 ALTERNATOR..................................................................................... 438 ELECTRIC WHEEL MOTORS.......................................................................... 438 RETARDING GRIDS................................................................................ 438 ELECTRONIC ACCELERATOR AND RETARD PEDALS....................................................... 438 Removal.................................................................................... 438 Installation............................................................................... 438 Disassembly................................................................................ 439 Reassembly................................................................................. 439 COOLING BLOWER WARNING SYSTEM.................................................................. 439 Operation.................................................................................. 439 Test....................................................................................... 439 Removal.................................................................................... 440 Installation............................................................................... 440 ELECTRICAL CONTROL CABINET..................................................................... 441 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS......................................... 446 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III............................................. 447 2-DIGIT DISPLAY PANEL SUBCODES..................................................................... 394 SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX....................................... 449 GENERAL INFORMATION................................................................................ 453 COMMUNICATIONS PORT CHECK.......................................................................... 454 PTU Hookup..................................................................................... 454 4.0 SEQUENCE TESTS - (ENGINE NOT ON)............................................................... 455 Preparation and Setup.......................................................................... 455 CONTROL SYSTEM SELF-TEST....................................................................... 456 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT....................................................... 456 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT......................................................... 457 PTU Setup.................................................................................. 457 4.3 REVERSER AND PROPULSION CONTACTORS CHECK................................................... 458 4.4 NOT USED................................................................................... 459 4.5 RETARD CONTACTORS OPERATION CHECK.......................................................... 459 4.6 GROUND FAULT SENSING CHECK................................................................. 459 4.7 GROUND FAULT IN RETARD OPERATION CHECK..................................................... 460 4.8 OVERRIDE OPERATION CHECK................................................................... 460 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK.......................................................... 461 4.10 OVERSPEED RETARD OPERATION CHECK.......................................................... 461 4.11 HOIST INTERLOCK OPERATION CHECK........................................................... 462 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.................................................. 462 Return to Main Menu........................................................................ 462 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL........................................... 463 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.............................................. 463 5.2 DIGITAL INPUT CHECKS....................................................................... 464 5.3 DIGITAL OUTPUT CHECKS...................................................................... 465 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL................................................... 469 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU................................................... 469 6.2 ANALOG INPUT CHECKS........................................................................ 470 6.3 FREQUENCY INPUT CHECKS..................................................................... 474 Return to Main Menu........................................................................ 475 7.0 SPEED EVENT CHECKS............................................................................. 475 Preparation and Setup.......................................................................... 475 Setup PTU...................................................................................... 475 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK.................................... 476 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK......................... 476 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK........................ 476 7.4 OTHER SPEED EVENTS CHECKS.................................................................. 476 Return to Main Menu........................................................................ 476 8.0 RETARD SPEED CONTROL SYSTEM CHECK.............................................................. 477 Preparation and Setup.......................................................................... 477 Setup PTU...................................................................................... 477 8.1 OVERSPEED PICKUP AND DROPOUT CHECK......................................................... 477 8.2 RETARD POT MAXIMUM SETTING CHECK........................................................... 477 8.3 RETARD POT MINIMUM SETTING CHECK........................................................... 477 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL......................................... 478 Return to Main Menu........................................................................ 478 9.0 LOAD TEST USING TRUCK RETARD GRIDS............................................................. 478 Setup and Preparation.......................................................................... 478 PTU Setup...................................................................................... 478 9.1 LOAD TEST.................................................................................. 479 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING........................................................ 479 Setup PTU...................................................................................... 479 10.1 RETARD CHECK.............................................................................. 480 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT................................................... 481 11.1 BRAKE SYSTEM INTERLOCKS CHECK............................................................. 481 Preparation................................................................................ 481 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT.................................................... 481 11.3 SYNC TRANSFORMER CHECKOUT................................................................. 482 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT................................................ 482 11.5 BATTERY BOOST ADJUSTMENT.................................................................. 482 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST............................................... 482 11.7 MOTOR ROTATION TEST....................................................................... 483 11.8 GROUND FAULT CHECKS....................................................................... 483 12.0 MISCELLANEOUS CHARTS.......................................................................... 484 12.1 WHEEL MOTOR GEAR RATIOS................................................................... 484 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS............................................................ 485 12.3 ENGINE.................................................................................... 486 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX............................................................ 487 SECTION G2 TIRES AND RIMS INDEX........................................................................ 489 GENERAL INFORMATION................................................................................ 491 TIRES.............................................................................................. 491 Handling Tires................................................................................. 491 Tire Maintenance............................................................................... 492 Storing Tires After Removal.................................................................... 492 FRONT TIRES AND RIMS............................................................................... 493 Removal........................................................................................ 493 Installation................................................................................... 494 REAR TIRES AND RIMS................................................................................ 495 Removal........................................................................................ 495 Installation................................................................................... 496 RIM............................................................................................ 497 Tire Removal................................................................................... 497 RIM AND TIRE PREPARATION........................................................................... 498 LUBRICANTS......................................................................................... 498 TIRE INSTALLATION.................................................................................. 499 SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX........................................................... 501 FRONT WHEEL HUB AND SPINDLE........................................................................ 503 WHEEL HUB AND SPINDLE ASSEMBLY................................................................. 503 Removal.................................................................................... 503 Installation............................................................................... 505 Disassembly................................................................................ 506 Cleaning and Inspection.................................................................... 507 Assembly................................................................................... 507 Wheel Bearing Adjustment (Spindle Vertical)................................................ 510 Wheel Bearing Adjustment (Tire Mounted).................................................... 511 Spindle Removal Procedure (Optional) (off of the truck).................................... 514 STEERING CYLINDERS AND TIE ROD................................................................. 516 Spherical Bearing Wear Limits.............................................................. 516 Removal.................................................................................... 517 Installation............................................................................... 519 Bearing Replacement........................................................................ 519 TOE-IN ADJUSTMENT.............................................................................. 520 SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX......................................................... 521 PIVOT PIN.......................................................................................... 523 Removal........................................................................................ 523 Installation................................................................................... 524 PIVOT EYE BEARING.................................................................................. 524 Disassembly.................................................................................... 524 Assembly....................................................................................... 525 PIVOT EYE REPAIR................................................................................... 525 Removal........................................................................................ 525 Disassembly.................................................................................... 525 Bushing (New).................................................................................. 525 Pivot Eye Bore (New)........................................................................... 525 Assembly....................................................................................... 525 Installation................................................................................... 526 ANTI-SWAY BAR...................................................................................... 526 Removal........................................................................................ 526 Installation................................................................................... 526 Disassembly.................................................................................... 527 Cleaning and Inspection........................................................................ 527 Assembly....................................................................................... 527 SECTION G5 REAR AXLE HOUSING INDEX..................................................................... 529 REAR AXLE HOUSING.................................................................................. 531 Removal........................................................................................ 531 Installation................................................................................... 531 WHEEL MOTOR........................................................................................ 531 Removal........................................................................................ 531 Cleaning and Inspection........................................................................ 532 Installation................................................................................... 532 Maximum Cap Screw Usage........................................................................ 532 SECTION H SUSPENSIONS INDEX................................................................................ 535 SECTION H2 FRONT SUSPENSION INDEX ..................................................................... 537 FRONT SUSPENSION................................................................................... 539 Removal........................................................................................ 539 Installation................................................................................... 540 TURN-OF-THE-NUT Tightening Procedure........................................................... 542 Upper Mounting Joint - 60° Advance......................................................... 542 Lower Mounting Joint - 90° Advance......................................................... 544 Inspection................................................................................. 544 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)............................................ 545 Bearing Structure Removal.................................................................. 545 Bearing Structure Installation............................................................. 545 MAJOR SUSPENSION REBUILD....................................................................... 546 Disassembly................................................................................ 546 Assembly................................................................................... 547 PRESSURE TEST.................................................................................. 549 SECTION H3 REAR SUSPENSIONS INDEX...................................................................... 551 Removal............................................................................................ 554 Installation....................................................................................... 556 Disassembly........................................................................................ 556 Cleaning and Inspection............................................................................ 557 Assembly........................................................................................... 557 SUSPENSION PRESSURE TEST........................................................................... 559 SECTION H4 OILING AND CHARGING PROCEDURES INDEX........................................................ 561 GENERAL............................................................................................ 563 EQUIPMENT LIST..................................................................................... 563 Hydrair® Charging Kit.......................................................................... 563 Installation of Charging Kit................................................................... 563 Removal of Charging Kit........................................................................ 564 Support Blocks For Oiling and Charging Dimensions.............................................. 564 FRONT SUSPENSION................................................................................... 565 Front Suspension Oiling........................................................................ 565 Front Suspension Nitrogen Charging............................................................. 566 REAR SUSPENSION.................................................................................... 568 Rear Suspension Oiling......................................................................... 568 Rear Suspension Nitrogen Charging.............................................................. 570 SECTION J BRAKE CIRCUIT INDEX.............................................................................. 573 SECTION J2 BRAKE CIRCUIT INDEX......................................................................... 575 GENERAL DESCRIPTION................................................................................ 577 SERVICE BRAKE CIRCUIT.............................................................................. 577 SECONDARY BRAKING AND AUTOMATIC APPLY.............................................................. 579 PARKING BRAKE CIRCUIT.............................................................................. 579 Normal Operation (key switch on, engine on).................................................... 579 BRAKE LOCK CIRCUIT................................................................................. 580 WARNING CIRCUIT.................................................................................... 580 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX....................................................... 583 BRAKE CIRCUIT COMPONENT SERVICE.................................................................... 585 BRAKE VALVE.................................................................................... 585 Rebuild Criteria........................................................................... 585 Removal.................................................................................... 585 Installation............................................................................... 587 Disassembly................................................................................ 589 Cleaning and Inspection.................................................................... 591 ASSEMBLY....................................................................................... 591 Actuator Base Threaded Inserts............................................................. 591 Boot and Cap............................................................................... 591 Valve Body Seal Installation............................................................... 592 Regulator Sleeve O-Ring Installation....................................................... 593 Actuator Plunger O-Ring Installation....................................................... 593 Assembly of Valve.......................................................................... 593 DIFFERENTIAL PRESSURE SWITCH................................................................... 594 Disassembly................................................................................ 595 Cleaning and Inspection.................................................................... 595 Assembly................................................................................... 595 VALVE BENCH TEST AND ADJUSTMENT................................................................ 595 Test Set Up Procedure...................................................................... 597 Brake Valve Output Pressure Adjustment..................................................... 597 Differential Pressure Switch Test.......................................................... 598 Final Test and Adjustment.................................................................. 598 Installation Of Brake Pedal Actuator Assembly to Brake Valve............................... 599 HYDRAULIC BRAKE ACCUMULATORS................................................................... 601 Brake Accumulator Bleed-Down Procedure..................................................... 601 Removal.................................................................................... 601 Installation............................................................................... 603 Disassembly................................................................................ 603 Cleaning and Inspection.................................................................... 605 Assembly................................................................................... 605 Leak Testing............................................................................... 608 BRAKE ACCUMULATOR CHARGING..................................................................... 609 Temperature During Precharge............................................................... 611 ACCUMULATOR STORAGE............................................................................ 611 Installation............................................................................... 612 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX..................................................... 613 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................................. 615 EQUIPMENT REQUIRED............................................................................. 618 INITIAL SYSTEM SET-UP.......................................................................... 619 Parking Brake.............................................................................. 619 Service Brakes............................................................................. 620 Brake Lock/Secondary....................................................................... 620 Low Brake Pressure and Auto Apply.......................................................... 621 Reapplications............................................................................. 621 Differential Pressure Switch............................................................... 621 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...................................................... 623 The Brakes are Locked, Service, and/or Parking................................................. 623 Both Brake Circuits are Dragging............................................................... 623 One Brake Circuit is Dragging.................................................................. 623 Brakes are Not Going to Full Pressure.......................................................... 623 A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off......................... 623 Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released.... 624 Differential Pressure Warning Circuit is Not Operating......................................... 624 A Low Brake Pressure Warning Occurs When Brakes are Applied.................................... 624 Low Pressure Warning Circuit Not Operating Properly............................................ 624 Low Pressure Warning is On Even Though System Pressure is Correct.............................. 625 Low Pressure Warning Comes On and Pressure is Low.............................................. 625 A Squeal is Heard When Controller is Operated.................................................. 625 Output Pressure At Controller is Correct but Brakes are Not Applying........................... 625 Brake Pressures Drift Excessively While Pedal is Held Steady................................... 625 Oil is Leaking Around the Pedal Base........................................................... 625 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM....................... 625 CHECK-OUT PROCEDURE................................................................................ 626 HYDRAULIC BRAKE SYSTEM DATA SHEET.................................................................. 626 SECTION J5 FRONT DISC BRAKES INDEX..................................................................... 629 BRAKE CALIPER...................................................................................... 631 Removal........................................................................................ 631 Installation................................................................................... 632 Disassembly.................................................................................... 633 Cleaning and Inspection........................................................................ 633 Assembly....................................................................................... 635 BRAKE LINING....................................................................................... 635 Replacement.................................................................................... 635 FRONT SERVICE BRAKE BURNISHING..................................................................... 637 BRAKE BLEEDING PROCEDURE....................................................................... 638 REAR DISC BRAKES................................................................................... 641 REAR BRAKES.................................................................................... 641 CALIPER, DISC, AND PARKING BRAKE............................................................... 641 Removal.................................................................................... 641 Installation............................................................................... 642 CALIPER PISTON................................................................................. 644 Piston Assembly Removal.................................................................... 644 Inspection................................................................................. 644 Piston Assembly Installation............................................................... 645 FUNCTIONAL TEST OF PISTON ASSEMBLY............................................................. 646 Return Spring Force........................................................................ 646 Built-In Clearance......................................................................... 646 Grip Force................................................................................. 648 Grip Force Measurement..................................................................... 649 Spring Force Measurement................................................................... 651 Disassembly of Piston Assembly............................................................. 652 Assembly of Piston Assembly................................................................ 653 BENCH TEST..................................................................................... 653 BRAKE LINING................................................................................... 654 Replacement................................................................................ 654 SERVICE BRAKE BURNISHING........................................................................... 657 SAFETY PRECAUTIONS............................................................................. 657 Rear Brake Burnishing...................................................................... 658 BRAKE BLEEDING PROCEDURE....................................................................... 659 Spring Force Measurement................................................................... 660 SECTION J6 REAR BRAKES INDEX........................................................................... 639 SECTION J7 PARKING BRAKE INDEX......................................................................... 661 GENERAL INFORMATION................................................................................ 663 PARKING BRAKE CALIPER.............................................................................. 663 Lining Thickness Inspection.................................................................... 663 Removal........................................................................................ 664 Installation................................................................................... 664 Parking Brake Adjustment....................................................................... 665 Parking Brake Caliper Disassembly.............................................................. 666 Cleaning and Inspection........................................................................ 667 Parking Brake Caliper Assembly................................................................. 668 PARKING BRAKE LINING REPLACEMENT................................................................... 668 PARKING BRAKE BURNISH PROCEDURE.................................................................... 668 Lining Conditioning............................................................................ 668 BRAKE BLEEDING PROCEDURE........................................................................... 669 SECTION L HYDRAULIC SYSTEM INDEX........................................................................... 671 SECTION L2 HYDRAULIC SYSTEM INDEX...................................................................... 673 GENERAL INFORMATION................................................................................ 675 HYDRAULIC SYSTEMS OPERATION........................................................................ 675 Hoist Circuit Operation........................................................................ 675 Steering Circuit Operation..................................................................... 677 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX..................................................... 681 HOIST PUMP......................................................................................... 683 Removal........................................................................................ 683 Installation................................................................................... 684 Disassembly.................................................................................... 685 Inspection of Parts............................................................................ 688 Assembly....................................................................................... 688 Troubleshooting Guide.......................................................................... 692 HYDRAULIC TANK..................................................................................... 693 Filling Instructions........................................................................... 693 Removal........................................................................................ 694 Installation................................................................................... 694 HYDRAULIC TANK STRAINER AND DIFFUSER............................................................... 695 Removal........................................................................................ 695 Inspect and Clean.............................................................................. 696 Installation................................................................................... 696 SECTION L4 STEERING CIRCUIT INDEX...................................................................... 697 STEERING CIRCUIT OPERATION......................................................................... 699 COMPONENT DESCRIPTION.............................................................................. 700 Steering Control Valve......................................................................... 700 Unloader Valve................................................................................. 701 Bleed-Down Manifold Valve...................................................................... 701 Flow Amplifier................................................................................. 706 FLOW AMPLIFIER SYSTEM OPERATION.................................................................... 707 No Steer....................................................................................... 707 Steering Left.................................................................................. 709 Steering Right................................................................................. 711 No Steer, External Shock Load.................................................................. 713 Steering Pump.................................................................................. 715 High Pressure Filter........................................................................... 715 Accumulators................................................................................... 715 Low Precharge Warning Switch................................................................... 715 SECTION L5 STEERING CONTROL VALVE INDEX................................................................ 717 Removal............................................................................................ 719 Installation....................................................................................... 720 STEERING CONTROL VALVE REBUILD..................................................................... 721 Disassembly.................................................................................... 721 Cleaning and Inspection........................................................................ 722 Assembly....................................................................................... 722 BRAKE / STEERING PUMP.............................................................................. 726 Removal........................................................................................ 726 Installation................................................................................... 728 Disassembly.................................................................................... 729 Inspection of Parts............................................................................ 729 Assembly....................................................................................... 731 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX..................................................... 733 STEERING CIRCUIT COMPONENT REPAIR.................................................................. 735 BLEED-DOWN MANIFOLD............................................................................ 735 Removal.................................................................................... 735 Installation............................................................................... 735 ACCUMULATOR.................................................................................... 736 Removal.................................................................................... 736 Installation............................................................................... 737 Disassembly................................................................................ 738 Cleaning and Inspection.................................................................... 738 Assembly................................................................................... 739 Leak Testing............................................................................... 740 STEERING ACCUMULATOR CHARGING.................................................................. 741 Temperature During Precharge............................................................... 744 ACCUMULATOR STORAGE............................................................................ 745 Installation............................................................................... 745 FLOW AMPLIFIER................................................................................. 746 Removal.................................................................................... 746 Installation............................................................................... 746 Disassembly................................................................................ 747 Assembly................................................................................... 750 STEERING CYLINDERS............................................................................. 751 Disassembly................................................................................ 751 Piston Seal and Bearing Installation....................................................... 751 Cylinder Assembly.......................................................................... 751 Test....................................................................................... 751 TROUBLESHOOTING CHART.............................................................................. 754 SECTION L7 HOIST CIRCUIT INDEX......................................................................... 759 HOIST CIRCUIT OPERATION............................................................................ 761 COMPONENT DESCRIPTION.............................................................................. 762 Hydraulic Tank................................................................................. 762 Hydraulic Pump................................................................................. 762 High Pressure Filter........................................................................... 762 Hoist Valve.................................................................................... 762 Hoist Pilot Valve.............................................................................. 763 Bleed-Down Manifold............................................................................ 764 Counterbalance Manifold........................................................................ 764 Hoist-Up Limit Solenoid........................................................................ 764 Pilot Operated Check Valve..................................................................... 764 HOIST VALVE OPERATION.............................................................................. 766 Float Operation................................................................................ 766 Power Up Operation (Figure 7-6)................................................................ 768 Hold Operation (Figure 7-7).................................................................... 770 Power Down Operation (Figure 7-8).............................................................. 772 Float Operation (Figure 7-9)................................................................... 774 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX........................................................ 777 HOIST VALVE........................................................................................ 779 Removal........................................................................................ 779 Installation................................................................................... 779 O-Ring Replacement............................................................................. 781 INLET SECTION...................................................................................... 782 Disassembly.................................................................................... 782 Cleaning and Inspection........................................................................ 783 Assembly....................................................................................... 783 REAR SPOOL SECTION (WORK PORTS).................................................................... 784 Disassembly.................................................................................... 784 Cleaning and Inspection........................................................................ 786 Assembly....................................................................................... 786 HOIST PILOT VALVE.................................................................................. 788 Removal........................................................................................ 788 Installation................................................................................... 788 Disassembly.................................................................................... 789 Cleaning and Inspection........................................................................ 790 Assembly....................................................................................... 790 HOIST UP LIMIT SOLENOID VALVE...................................................................... 791 HOIST CYLINDERS.................................................................................... 792 Removal........................................................................................ 792 Installation................................................................................... 793 Disassembly.................................................................................... 795 Cleaning and Inspection........................................................................ 796 SS1143 Tightening Tool - Assembly Drawing...................................................... 797 ASSEMBLY OF QUILL AND CYLINDER..................................................................... 797 Quill Installation............................................................................. 797 Installation Of Check Balls And Plugs In Quill................................................. 798 Assembly of Cylinder........................................................................... 800 Pressure Testing............................................................................... 801 COUNTERBALANCE MANIFOLD............................................................................ 801 SECTION L9 HIGH PRESSURE FILTERS INDEX................................................................. 803 HOIST CIRCUIT FILTER............................................................................... 805 Filter Element Replacement..................................................................... 805 Removal........................................................................................ 806 Installation................................................................................... 806 Indicator Switch............................................................................... 806 STEERING CIRCUIT FILTER............................................................................ 807 Filter Element Replacement..................................................................... 807 Removal........................................................................................ 808 Installation................................................................................... 808 Indicator Switch............................................................................... 808 INDICATOR SWITCH................................................................................... 808 Test Procedure................................................................................. 808 SECTION L10 HYDRAULIC CHECK-OUT PROCEDURE INDEX........................................................ 811 INITIAL START UP AND FLUSHING...................................................................... 813 COMPONENT CHECKOUT AND ADJUSTMENT.................................................................. 815 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE...................................... 817 Counterbalance Valve Adjustment................................................................ 819 Manifold Assembly.............................................................................. 819 OIL CLEANLINESS CHECK.............................................................................. 819 Oil Sampling Location On Truck................................................................. 819 Oil Sampling Process and Cleanliness Criteria.................................................. 820 DISABLED TRUCK DUMPING PROCEDURE................................................................... 820 Hookup......................................................................................... 820 Raising the Body............................................................................... 820 Lowering the Body.............................................................................. 821 TROUBLESHOOTING CHART.............................................................................. 822 Hoist Pump..................................................................................... 822 Steering Circuit............................................................................... 824 Brake/Steering Pump............................................................................ 826 Flow Amplifier - Refer to Figure 10-9.......................................................... 828 SECTION M OPTIONS AND SPECIAL TOOLS INDEX ................................................................. 829 SECTION M7 HEATER OPTIONS INDEX........................................................................ 831 GENERAL INFORMATION................................................................................ 833 TROUBLESHOOTING.................................................................................... 833 HEATER ELEMENT..................................................................................... 833 Removal........................................................................................ 833 Installation................................................................................... 834 GENERAL............................................................................................ 835 Maintenance.................................................................................... 835 HEATING ELEMENT.................................................................................... 835 Removal........................................................................................ 835 Installation................................................................................... 836 THERMOSTAT......................................................................................... 836 Removal........................................................................................ 836 Installation................................................................................... 836 GENERAL INFORMATION................................................................................ 837 TROUBLESHOOTING.................................................................................... 837 HEATER ELEMENT..................................................................................... 837 Removal........................................................................................ 837 Installation................................................................................... 838 SECTION M8 SPECIAL TOOLS INDEX ....................................................................... 839 NITROGEN CHARGING VALVE............................................................................ 839 ROLL-OUT ASSEMBLY.................................................................................. 839 EYE BOLT........................................................................................... 839 OFFSET WRENCH...................................................................................... 840 TORQUE ADAPTER..................................................................................... 840 HANDLE............................................................................................. 840 SEAL INSTALLER..................................................................................... 840 SLEEVE ALIGNMENT TOOLS............................................................................. 841 QUICK DISCONNECT COUPLING.......................................................................... 841 HARNESS............................................................................................ 841 SEAL INSTALLATION RING............................................................................. 841 BELT TENSION TESTER................................................................................ 842 BELT ALIGNMENT TOOL................................................................................ 842 SOCKETS AND ADAPTERS............................................................................... 842 DUST CAPS.......................................................................................... 842 HYDRAULIC SYSTEM FLUSHING TOOLS.................................................................... 843 PAYLOAD DATA MANAGER............................................................................... 843 HYDRAULIC SYSTEM VACUUM PUMP....................................................................... 843 MISCELLANEOUS SERVICE TOOLS........................................................................ 844 HIGH VOLTAGE TOOLS................................................................................. 847 2000 VDC METER..................................................................................... 847 GROUNDING STICKS................................................................................... 847 BODY PAD SPACER TOOL............................................................................... 848 SECTION M19 RADIATOR SHUTTERS INDEX.................................................................... 849 SECTION N OPERATOR'S CAB INDEX............................................................................. 859 SECTION N2 TRUCK CAB INDEX............................................................................. 861 TRUCK CAB.......................................................................................... 863 TRUCK CAB...................................................................................... 863 Description................................................................................ 863 Removal.................................................................................... 864 Installation............................................................................... 866 CAB DOOR....................................................................................... 866 Removal.................................................................................... 866 Installation............................................................................... 867 Door Adjustment............................................................................ 867 Door Jam Bolt Adjustment................................................................... 867 Door Handle Plunger Adjustment............................................................. 869 Replace Door Glass......................................................................... 870 Replace Door Window Regulator.............................................................. 874 Replace Door Handle or Latch Assembly...................................................... 874 Door and Door Hinge Seal Replacement....................................................... 875 Door Opening Seal Removal.................................................................. 875 Installation............................................................................... 875 GLASS REPLACEMENT.............................................................................. 876 Adhesive-Bonded Windows.................................................................... 876 Recommended Tools/Supplies................................................................. 876 Replacement Procedure...................................................................... 876 Windshield and Rear Glass.................................................................. 877 Removal.................................................................................... 877 Installation............................................................................... 878 REMOVAL AND INSTALLATION OF OPERATOR SEAT...................................................... 879 Inspection................................................................................. 879 Removal.................................................................................... 879 Installation............................................................................... 879 REMOVAL AND INSTALLATION OF PASSENGER SEAT..................................................... 880 Removal.................................................................................... 880 Installation............................................................................... 880 SECTION N3 CAB COMPONENTS INDEX........................................................................ 881 WINDSHIELD WIPERS.................................................................................. 883 WIPER MOTOR REPLACEMENT........................................................................ 883 Removal.................................................................................... 883 Installation............................................................................... 883 WIPER ARM REPLACEMENT.......................................................................... 883 Removal.................................................................................... 883 Installation............................................................................... 884 WIPER LINKAGE REPLACEMENT...................................................................... 884 Removal.................................................................................... 884 Installation............................................................................... 885 WINDSHIELD WASHER.............................................................................. 885 Operation.................................................................................. 885 Service.................................................................................... 885 SEAT BELT...................................................................................... 886 Removal.................................................................................... 886 Installation............................................................................... 886 SECTION N4 OPERATOR COMFORT INDEX...................................................................... 889 HEATER / AIR CONDITIONER........................................................................... 891 Fan Speed Control Knob......................................................................... 891 Temperature Control Knob....................................................................... 891 Air Flow Directional Knob...................................................................... 891 Heater/Air Conditioner Vents................................................................... 892 COMPONENTS......................................................................................... 892 Fuse and Circuit Breaker....................................................................... 892 Relays......................................................................................... 892 Heater Core.................................................................................... 892 Fan Motor And Speed Control.................................................................... 893 Actuators...................................................................................... 893 Cab Air Filter................................................................................. 893 ENVIRONMENTAL IMPACT OF AIR CONDITIONING........................................................... 896 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.......................................................... 896 PRINCIPLES OF REFRIGERATION........................................................................ 896 Air Conditioning............................................................................... 896 Refrigeration - The Act Of Cooling............................................................. 897 The Refrigeration Cycle........................................................................ 897 AIR CONDITIONER SYSTEM COMPONENTS.................................................................. 898 Compressor (Refrigerant Pump).................................................................. 898 Service Valves................................................................................. 898 Condenser...................................................................................... 898 Receiver-Drier................................................................................. 898 Expansion Block Valve.......................................................................... 899 Accumulator.................................................................................... 899 Evaporator..................................................................................... 899 ELECTRICAL CIRCUIT................................................................................. 900 Thermostat..................................................................................... 900 Compressor Clutch.............................................................................. 900 Trinary™ Switch................................................................................ 901 SYSTEM SERVICING................................................................................... 902 SERVICE TOOLS AND EQUIPMENT........................................................................ 903 Recovery/Recycle Station....................................................................... 903 Leak Detector.................................................................................. 903 Service Valves................................................................................. 904 Vacuum Pump.................................................................................... 904 Manifold Gauge Set............................................................................. 905 Installing Manifold Gauge Set.................................................................. 906 Purging Air From Service Hoses................................................................. 906 SYSTEM PERFORMANCE TEST............................................................................ 907 SYSTEM OIL......................................................................................... 908 Handling and Reusing PAG Oil................................................................... 908 Oil Quantity................................................................................... 908 Checking System Oil............................................................................ 908 REFRIGERANT........................................................................................ 909 Recycled Refrigerant........................................................................... 909 Reclaimed Refrigerant.......................................................................... 909 Refrigerant Quantity........................................................................... 909 R-134a Refrigerant Containers.................................................................. 910 SYSTEM LEAK TESTING................................................................................ 910 Electronic Leak Detector....................................................................... 911 Tracer Dyes.................................................................................... 911 Soap and Water................................................................................. 911 RECOVERING AND RECYCLING THE REFRIGERANT........................................................... 911 Draining Oil from the Previous Recovery Cycle.................................................. 911 Performing the Recovery Cycle.................................................................. 911 Performing the Recycling Procedure............................................................. 912 Evacuating and Charging the A/C System......................................................... 912 SYSTEM REPAIR...................................................................................... 912 System Flushing................................................................................ 912 A/C DRIVE BELT CHECKOUT PROCEDURE.................................................................. 913 Pulley Alignment............................................................................... 913 Belt Tension Check............................................................................. 913 COMPONENT REPLACEMENT.............................................................................. 915 Hoses and Fittings............................................................................. 915 Lines.......................................................................................... 915 Expansion Valve................................................................................ 915 Receiver-Drier................................................................................. 915 Thermostat..................................................................................... 915 Compressor..................................................................................... 916 Accumulator.................................................................................... 916 Clutch......................................................................................... 916 Servicing the Compressor Clutch................................................................ 917 Pulley Removal................................................................................. 919 Clutch Coil Check.............................................................................. 920 Pulley Installation............................................................................ 920 Clutch Assembly Installation................................................................... 920 EVACUATING THE SYSTEM.............................................................................. 922 CHARGING THE A/C SYSTEM............................................................................ 924 Preliminary Checks............................................................................. 925 Diagnosis Of Gauge Readings And System Performance............................................. 925 SECTION N5 OPERATOR CONTROLS AND EQUIPMENT INDEX....................................................... 933 OPERATOR CAB AND CONTROLS.......................................................................... 935 STEERING WHEEL AND CONTROLS........................................................................ 936 HORN BUTTON.................................................................................... 936 TILT/TELESCOPE LEVER........................................................................... 936 M ULTI-FUNCTION TURN SIGNAL SWITCH............................................................. 936 Turn Signal Operation...................................................................... 936 High Beam Headlight Operation.............................................................. 936 Windshield Wiper Operation................................................................. 936 STEERING COLUMN................................................................................ 937 Removal.................................................................................... 937 Inspection................................................................................. 937 Installation............................................................................... 938 STEERING WHEEL................................................................................. 938 Removal.................................................................................... 938 Installation............................................................................... 938 PEDALS............................................................................................. 940 SERVICE BRAKE PEDAL............................................................................ 940 DYNAMIC RETARDER PEDAL......................................................................... 940 Optional - Dual Function/Single Pedal...................................................... 940 THROTTLE PEDAL................................................................................. 940 GRADE/SPEED WARNING CHART...................................................................... 941 OVERHEAD PANEL CONTROLS AND COMPONENTS............................................................. 941 RADIO SPEAKERS................................................................................. 941 WARNING ALARM BUZZER........................................................................... 941 CAB RADIO...................................................................................... 941 WARNING LIGHTS DIMMER CONTROL.................................................................. 941 WARNING/STATUS INDICATOR LIGHT PANEL........................................................... 941 AIR CLEANER VACUUM GAUGES...................................................................... 941 WINDSHIELD WIPERS.............................................................................. 941 TRUCK CONTROLS................................................................................. 942 F-N-R Selector Switch...................................................................... 942 Hoist Control Lever........................................................................ 943 CONSOLE SWITCHES AND CONTROLS.................................................................. 943 Ashtray.................................................................................... 943 Cigarette Lighter.......................................................................... 943 Left-Hand Window Control Switch............................................................ 943 Right-Hand Window Control Switch........................................................... 943 Engine Shutdown Switch..................................................................... 943 Override Switch............................................................................ 943 Retard Speed Control (RSC) Switch.......................................................... 944 Retard Speed Control (RSC) Dial............................................................ 944 Statex III Download Port................................................................... 945 Engine Diagnostic Port (CENSE)............................................................. 945 Modular Mining Port........................................................................ 945 Passenger Seat............................................................................. 945 Engine Diagnostic Connectors............................................................... 945 Engine Diagnostics Connector............................................................... 945 Data Store Button.......................................................................... 945 PAYLOAD METER.................................................................................. 945 Payload Meter Download Connector........................................................... 945 OPERATOR’S SEAT.................................................................................... 946 Seat Belts..................................................................................... 946 Adjustment..................................................................................... 946 INSTRUMENT PANEL................................................................................... 947 CONTROL SYMBOLS................................................................................ 947 CONTROL SWITCHES AND GAUGES.................................................................... 948 Key Switch................................................................................. 948 Engine Shutdown Switch With Timer Delay.................................................... 949 Fog Light Switch........................................................................... 949 Ladder Light Switch........................................................................ 949 Backup Light Switch........................................................................ 949 Panel Illumination Lights.................................................................. 949 Cab Air Conditioner/Heater Vents........................................................... 949 Engine Cold Weather Starting Aid Switch.................................................... 949 Rotating Beacon Light Switch............................................................... 949 Heated Mirror Switch....................................................................... 949 Leakage Test Switch (Trolley Option Only).................................................. 949 Wheel Brake Lock Switch.................................................................... 950 Parking Brake Switch....................................................................... 950 Digital Tachometer......................................................................... 950 Right Turn Signal Indicator Light.......................................................... 951 High Beam Headlight Indicator Light........................................................ 951 Left Turn Signal Indicator Light........................................................... 951 Digital Speedometer/Payload Meter Display.................................................. 951 Voltmeter Gauge............................................................................ 951 Engine Oil Pressure Gauge.................................................................. 951 Engine Water Temperature Gauge............................................................. 951 Fuel Gauge................................................................................. 951 Engine Hourmeter........................................................................... 951 Headlight Switch........................................................................... 952 Panel Illumination Lights Dimmer Rheostat.................................................. 952 Payload Meter Switch....................................................................... 952 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL...................................................... 953 DESCRIPTION OF INDICATOR SYMBOLS............................................................... 953 INDICATOR LIGHT FUNCTIONS...................................................................... 954 A1. High Hydraulic Oil Temperature......................................................... 954 B1. Low Steering Pressure.................................................................. 954 C1. Low Accumulator Precharge Pressure..................................................... 955 D1. Electric System Fault.................................................................. 955 E1. Low Brake Pressure..................................................................... 955 A2. Low Hydraulic Tank Level............................................................... 955 B2. Automatic Lubrication System Pressure.................................................. 955 C2. Circuit Breaker Tripped................................................................ 955 D2. Hydraulic Oil Filter Monitor........................................................... 956 E2. Low Fuel............................................................................... 956 A3. Parking Brake.......................................................................... 956 B3. Service Brake.......................................................................... 956 C3. Body Up................................................................................ 956 D3. Dynamic Retarding...................................................................... 956 E3. Stop Engine............................................................................ 956 A4. Not Used............................................................................... 957 B4. Manual Backup Lights................................................................... 957 C4. Engine Shutdown Timer.................................................................. 957 D4. Retard Speed Control (RSC)............................................................. 957 E4. Check Engine........................................................................... 957 A5. Service Engine Indicator (AEM)......................................................... 957 B5. High Wheel Motor Temperature........................................................... 957 C5. Blower Fault........................................................................... 957 D5, E5, A6, B6, and C6. Not Used........................................................... 957 D6. Service Engine (CENSE)................................................................. 957 E6. Not Used............................................................................... 957 Komatsu Engines w/Centry™ Fuel Control..................................................... 958 Hazard Warning Light Switch................................................................ 958 Lamp Test Switch/Centry™ Diagnostic Test Switch............................................ 958 REAR AXLE LIGHT BAR................................................................................ 959 Backup Lights.................................................................................. 959 Retard Lights.................................................................................. 959 Brake Light.................................................................................... 959 Backup Alarm................................................................................... 959 KOMTRAX Plus................................................................................... 960 Operation.................................................................................. 960 Interface Module........................................................................... 962 Basic Precautions.......................................................................... 962 CENTRY™ FUEL SYSTEM DIAGNOSTICS.................................................................... 963 GENERAL OPERATION.............................................................................. 963 DETERMINING FAULT CODES........................................................................ 963 EXITING THE DIAGNOSTICS MODE................................................................... 964 SECTION P LUBRICATION AND SERVICE INDEX.................................................................... 965 SECTION P2 LUBRICATION AND SERVICE INDEX............................................................... 967 GENERAL INFORMATION................................................................................ 969 HYDRAULIC TANK SERVICE............................................................................. 969 Adding Oil..................................................................................... 969 COOLANT LEVEL CHECK................................................................................ 970 Radiator Filling Procedure..................................................................... 970 Coolant Specifications......................................................................... 970 Unacceptable Practices......................................................................... 970 WHEEL MOTOR SERVICE................................................................................ 970 RESERVE ENGINE OIL SYSTEM (Optional)............................................................... 971 Reserve Oil Tank Filling Procedure (Remote fill)............................................... 971 Inline Screen.................................................................................. 971 QUICK FILL SERVICE CENTER.......................................................................... 972 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS........................................................ 974 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)............................................ 975 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................................... 976 100 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 976 250 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 977 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)............................................ 978 500 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 979 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)............................................ 980 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 981 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 982 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 982 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 983 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................................... 984 SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX.......................................................... 985 GENERAL DESCRIPTION................................................................................ 987 SYSTEM COMPONENTS.................................................................................. 988 Filter Assembly................................................................................ 988 Hydraulic Motor and Grease Pump................................................................ 988 Reservoir...................................................................................... 988 Fixed Pressure Reducing Valve.................................................................. 988 Flow Control Valve............................................................................. 988 Solenoid Valve................................................................................. 989 Vent Valve..................................................................................... 989 24VDC Lubrication Cycle Timer.................................................................. 989 Time Delay Module.............................................................................. 989 Pump Cutoff Pressure Switch.................................................................... 989 Unloader Valve................................................................................. 989 Pressure Switch................................................................................ 989 Manual Override Button......................................................................... 989 Injectors...................................................................................... 989 SYSTEM OPERATION................................................................................... 992 Normal Operation............................................................................... 992 Pressure Failure Detection Circuits............................................................ 993 GENERAL INSTRUCTIONS............................................................................... 994 LUBRICANT REQUIRED FOR SYSTEM.................................................................. 994 SYSTEM PRIMING................................................................................. 994 LUBRICANT PUMP................................................................................. 995 Pump Housing Oil Level..................................................................... 995 Pump Pressure Control...................................................................... 995 FILTER AND RESERVOIR........................................................................... 995 Filter Assembly Element.................................................................... 996 INJECTORS (SL-1 Series H)...................................................................... 996 Injector Specifications.................................................................... 996 Injector Adjustment........................................................................ 996 INJECTOR OPERATION............................................................................. 998 SYSTEM CHECKOUT................................................................................ 999 Lubrication Cycle Timer Check.............................................................. 999 Lubrication Cycle Timer Adjustment.........................................................1000 PREVENTIVE MAINTENANCE INSPECTION..............................................................1000 10 Hour Lubrication System Inspection......................................................1000 100 Hour Inspection........................................................................1000 250 Hour Inspection........................................................................1000 500 Hour Inspection........................................................................1001 1000 Hour Inspection.......................................................................1001 PUMP REBUILD...................................................................................1002 Disassembly................................................................................1002 Cleaning and Inspection....................................................................1002 Assembly...................................................................................1004 VENT VALVE REBUILD.............................................................................1005 Disassembly and Assembly...................................................................1005 SYSTEM TROUBLESHOOTING CHART...................................................................1006 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1011 AXLE BOX.......................................................................................1011 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1012 ARMATURE AREA..................................................................................1012 AT TIRE CHANGE.................................................................................1012 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1013 GENERATOR/ALTERNATOR...........................................................................1013 GRID BLOWER MOTOR..............................................................................1013 CONTROL EQUIPMENT CHECKS.......................................................................1013 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................1014 VEHICLE OPERATIONS TESTS.......................................................................1014 SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX..................................................1009 SECTION R SYSTEM SCHEMATICS INDEX..........................................................................1015 EF5755 HYDRAULIC BRAKE SCHEMATIC ......................................................................1017 EJ2729 HYDRAULIC SCHEMATIC.............................................................................1018 EL8720 VHMS ELECTRICAL SCHEMATIC.......................................................................1019 HE484 HVAC ELECTRICAL SCHEMATIC .......................................................................1024 XS8600 ................................................................................................1025 XS8601.............................................................................................1025 XS8602.............................................................................................1026 XS8603.............................................................................................1027 XS8604.............................................................................................1028 XS8605.............................................................................................1029 XS8606.............................................................................................1030 XS8607.............................................................................................1031 XS8608.............................................................................................1032 XS8609.............................................................................................1033 XS8610.............................................................................................1034 XS8611.............................................................................................1035 XS8612.............................................................................................1036 XS8613.............................................................................................1037 XS8614.............................................................................................1038 XS8615.............................................................................................1039 XS8616.............................................................................................1040 XS8617.............................................................................................1041 XS8618.............................................................................................1042 XS8619.............................................................................................1043 XS8620.............................................................................................1044 XS8621.............................................................................................1045 XS8622.............................................................................................1046 XS8623.............................................................................................1047 XS8624.............................................................................................1048 XS8625.............................................................................................1049 XS8626.............................................................................................1050 XS8627.............................................................................................1051
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