Komatsu 730E DUMP TRUCK – TROLLEY Shop Manual CEBM025001 – PDF

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Komatsu 730E DUMP TRUCK – TROLLEY Shop Manual CEBM025001 – PDF DOWNLOAD

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Komatsu 730E DUMP TRUCK – TROLLEY Shop Manual CEBM025001 – PDF DOWNLOAD

Language : English
Pages : 1032
Downloadable : Yes
File Type : PDF

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Komatsu 730E DUMP TRUCK – TROLLEY Shop Manual CEBM025001 – PDF DOWNLOAD

• SERIAL NUMBERS    730E A30617 and up
  ENGINE                       16V159

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION 9
SECTION A2 MAJOR COMPONENT DESCRIPTION INDEX 11
Truck And Engine 11
Alternator (GTA-22) 11
Wheel Motors (788) 11
Blower 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
Suspension 11
SECTION A2 SPECIFICATIONS 13
SECTION A3 GENERAL SAFETY AND OPERATION INDEX 15
GENERAL SAFETY AND OPERATION 18
PERSONAL SAFETY 18
Safety Rules 18
Truck Safety Features 18
Clothing And Personal Items 18
Unauthorized Modification 18
Leaving The Operator’s Seat 18
Mounting And Dismounting 19
Fire Extinguishers And First Aid Kits 19
Precautions For High Temperature Fluids 19
Asbestos Dust Hazard Prevention 19
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 20
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 23
Starting The Engine 23
Truck Operation – General 23
Traveling In The Truck 24
Precautions When Traveling In Reverse 24
Traveling On Slopes 24
Ensuring Good Visibility 24
Operating On Snow 24
Avoid Damage To The Dump Body 24
Driving Near High-Voltage Cables 25
When Loading The Truck 25
When Dumping 25
Working On Loose Ground 25
Parking The Machine 25
TOWING 26
WORKING NEAR BATTERIES 26
Battery Hazard Prevention 26
Jump-Starting With Booster Cables 27
Jump Starting With Receptacles 27
PRECAUTIONS FOR MAINTENANCE 28
BEFORE PERFORMING MAINTENANCE 28
Stopping The Engine Before Service 28
Warning Tag 28
Proper Tools 28
Securing The Dump Body 28
DURING MAINTENANCE 29
Personnel 29
Attachments 29
Working Under The Machine 29
Keeping The Machine Clean 29
Rules To Follow When Adding Fuel Or Oil 29
Radiator Cool ant Leve l 29
Use Of Lighting 29
Precautions With The Battery 30
Handling High-Pressure Hoses 30
Precautions With High-Pressure Oil 30
Maintenance Near High Temperatures And High Pressures 30
Rotating Fan And Belts 30
Waste Materials 30
Use of Tie-Off Anchor During Maintenance and Repair 30
TIRES 31
Handling Tires 31
Tire Maintenance 32
Storing Tires After Removal 32
ADDITIONAL JOB SITE RULES 33
WHEN REPAIRS ARE NECESSARY 34
OPERATING INSTRUCTIONS 35
PREPARING FOR OPERATION 35
SAFETY IS THINKING AHEAD 35
WALK AROUND INSPECTION 35
ENGINE START-UP 39
AFTER ENGINE HAS STARTED 40
EMERGENCY STEERING SYSTEM 41
Operation 41
Pre-Operation Testing 41
Additional Guidelines 42
MACHINE OPERATION SAFETY PRECAUTIONS 42
LOADING 43
HAULING 43
PASSING 44
DUMPING 44
To Raise The Dump Body: 44
To Lower The Dump Body: (When dumping over a berm or into a crusher): 45
To Lower The Dump Body (When dumping on flat ground): 45
TOWING 46
Towing Procedure 46
SAFE PARKING PROCEDURES 47
ENGINE SHUTDOWN PROCEDURE 47
DELAYED ENGINE SHUTDOWN PROCEDURE 47
SUDDEN LOSS OF POWER 48
TROLLEY OPERATING INSTRUCTIONS 49
AFTER THE ENGINE HAS STARTED 49
OPERATING IN DIESEL MODE 49
OPERATING IN TROLLEY LINE MODE 50
GETTING ON LINE 50
Operating On Trolley 52
GETTING OFF LINE 53
LINE STATUS SIGNALS 53
LINE STATUS SIGNAL MARKINGS 54
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION 54
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK 54
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS 55
TRUCK FAILURE WHILE ON TROLLEY 55
SECTION A4 WARNINGS AND CAUTIONS INDEX 57
LUBRICATION CHART 65
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS INDEX 67
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 68
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 68
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 69
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 70
SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX 77
STORAGE AND IDLE MACHINE PREPARATION 79
SHORT TERM IDLE PERIODS 79
PREPARATION FOR STORAGE 80
REMOVAL FROM STORAGE 81
RECONDITIONING AN IDLE VEHICLE 82
ENGINE OPERATION 85
After The Engine Has Started 85
ENGINE STORAGE 86
Temporary Storage (30 Days Or Less) 86
Extended Storage (More Than 30 Days) 87
RESTORING AN ENGINE AFTER EXTENDED STORAGE 88
ELECTRIC DRIVE TRUCKS 89
Storing A Truck That Is Operational 89
Storing A Truck That Is Not Operational 90
Storing A Major Component 91
Periodic Inspections 91
Placing Equipment Into Service After Storage 91
SECTION B STRUCTURES 93
SECTION B2 STRUCTURAL COMPONENTS INDEX 95
STRUCTURAL COMPONENTS 97
LADDERS 97
Removal 97
Installation 97
GRILLE AND HOOD 98
Removal 98
Installation 98
RIGHT-HAND DECK 98
Removal 98
Installation 100
CENTER DECK 100
LEFT-HAND DECK 101
Removal 101
Installation 101
SECTION B3 DUMP BODY INDEX 103
DUMP BODY 105
Removal 105
Installation 106
BODY SLING 106
BODY PADS 107
BODY GUIDE 107
Adjustment 107
BODY POSITION INDICATOR 108
HOIST LIMIT SWITCH 108
ROCK EJECTORS 108
Inspection 108
SECTION B4 FUEL TANK INDEX 109
FUEL TANK 111
Removal 111
Repair 111
Cleaning 111
Installation 112
FUEL GAUGE SENDER 113
Removal 113
Installation 113
LOW FUEL SENDER 114
Removal 114
Installation 114
TANK BREATHER VALVE 115
Removal 115
Installation 115
Disassembly 115
Assembly 115
FUEL RECEIVER (WIGGINS QUICK FILL) 116
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL) 117
SECTION C ENGINE 119
SECTION C2 POWER MODULE INDEX 121
POWER MODULE 123
GENERAL INFORMATION 123
POWER MODULE SERVICE 124
Removal 124
Installation 128
EXHAUST TUBE INSTALLATION 132
EXHAUST BLANKET INSTALLATION 132
SECTION C3 COOLING SYSTEM INDEX 133
COOLING SYSTEM 135
RADIATOR 135
Removal 135
Service 136
Installation 136
RADIATOR FILL PROCEDURE 137
RADIATOR REPAIR 137
Internal Inspection 137
External Cleaning 138
Disassembly 138
Cleaning and Inspection 139
Assembly 140
Additional Service Information 141
PRESSURE TESTING 141
COOLANT SYSTEM TROUBLESHOOTING 141
SECTION C4 POWER TRAIN INDEX 143
POWER TRAIN 145
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 145
General Information 145
Removal 145
ALTERNATOR INSTALLATION 147
Engine/Alternator Mating 147
Alternator Measurement 147
Engine End Play Measurement 148
Determining Shim Requirements 149
Installing Alternator On Engine 150
ENGINE 152
Removal 152
Installation 152
SECTION C5 AIR CLEANERS INDEX 153
AIR CLEANERS 155
OPERATION 155
SERVICING THE AIR CLEANERS 155
Replacing The Elements 156
AIR CLEANER ASSEMBLY CLEANING 157
Primary Element Cleaning 157
Precleaner Section Cleaning 159
AIR INTAKE TROUBLESHOOTING 160
SECTION C7 FAN DRIVE CLUTCH INDEX 161
FAN DRIVE CLUTCH 163
GENERAL DESCRIPTION 163
COMPONENTS 163
Input 163
Output 163
Stationary Components 164
OPERATIONAL MODES 165
Fully Engaged 165
Modulated Variable Speed 165
Fully Released 166
Lubricating and Cooling Oil 167
MAINTENANCE 168
TROUBLESHOOTING 169
Preliminary Checks 169
FIELD CHECK DIAGNOSIS 170
Preliminary Checks – Engine Off 170
Check Clutch Release 170
Check Clutch Lock-up 171
Overheating 171
Thermal Sensor and Solenoid Valve 172
On Truck Test 172
Off Truck Test 172
TROUBLESHOOTING CHART 174
FAN CLUTCH DISASSEMBLY INSTRUCTIONS 177
REASSEMBLY OF THE FAN CLUTCH 184
INSPECTION OF PARTS 195
REBUILD TOOLS 199
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 201
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 203
24VDC ELECTRIC SUPPLY SYSTEM 205
ELECTRICAL SYSTEM DESCRIPTION 205
BATTERIES 205
Maintenance and Service 205
Troubleshooting 205
BATTERY CHARGING ALTERNATOR 207
24VDC ELECTRIC START SYSTEM 207
CRANKING MOTORS 207
Removal 207
Installation 208
CRANKING MOTOR TROUBLESHOOTING 208
Preliminary Inspection 209
No-Load Test 209
Interpreting Results of Tests 209
Disassembly 210
Cleaning and Inspection 210
Armature Servicing 211
Field Coil Checks 213
Field Coil Removal 213
Solenoid Checks 213
Test 213
Assembly 215
Pinion Clearance 216
MAGNETIC SWITCH 216
Coil Test 216
Electric Start System Wiring Diagrams 216
ENGINE PRELUB SYSTEM 217
OPERATION 217
Pressure Switch 217
Suction Line 217
Outlet Line 217
Check Valve 217
Solenoid Timer 217
TROUBLESHOOTING PRELUB STARTER CIRCUIT 219
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 223
24VDC ELECTRICAL SYSTEM COMPONENTS 225
PASSENGER SEAT BASE COMPARTMENT 225
COMPONENTS 225
Taillight Resistor Diode Assemblies 225
Inclinometer 225
Lubrication System Timer 225
Three Minute Idle Timer Components 225
Three Minute Idle Timer 227
Idle Timer Relay 227
Three Minute Idle Contactor 227
Three Minute Idle Circuit Test 227
Data Store Button 227
Komatsu Engine Diagnostic Connector (Centry) 227
Komatsu Engine Diagnostic Port (CENSE) 227
STATEX III Propulsion System Diagnostic Connector 227
Alarm Indicating Device (AID) System 228
Diode Matrix (Without Sound) 228
Diode Matrix (With Sound) 229
Hot Switch Inverter 229
Hot Switch Inverter Card (Slot 4) (Not Used) 229
Temperature 229
Oil Level 229
Temperature and Latch 229
Coolant Level/Flasher 230
Lamp Test 230
BATTERY EQUALIZER BOX 230
Troubleshooting 230
BODY POSITION SWITCHES 232
Proximity Switch Operation 232
Body-Up Switch Adjustment 233
Hoist Limit Switch Adjustment 233
24-VOLT RELAY AND DIODE BOARDS 235
RELAY BOARDS 236
Description 236
SERVICE 236
To Replace A Relay: 236
To Replace A Circuit Breaker: 236
To Replace A Circuit Panel Card 237
Relay Board Components 237
Installing Additional Circuits 238
DIODE BOARD 1 239
Diode Testing 239
CIRCUIT BREAKERS 241
SECTION D10 CHARGING SYSTEM INDEX 243
CHARGING SYSTEM 245
CHARGING SYSTEM DESCRIPTION 245
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION 245
Excessive heat 245
Dirt and dust 245
Vibration 245
PREVENTIVE MAINTENANCE PROCEDURES 246
Alternator Cleanliness 246
Alternator Mounting 246
Belt Tension And Condition 246
TROUBLESHOOTING PROCEDURES 246
ALTERNATOR PERFORMANCE TEST 246
ALTERNATOR PERFORMANCE TEST – LOAD APPLIED 247
ALTERNATOR CABLE TEST 247
VOLTAGE REGULATOR ADJUSTMENT 248
ALTERNATOR 249
Removal 249
Installation 250
SECTION D35 PAYLOAD METER III INDEX 253
OPERATION SECTION 258
INTRODUCTION 258
Data Summary 258
Data Gathering 258
COMPONENT DESCRIPTION 259
System Diagram 259
Suspension Pressure Sensors 259
Inclinometer 259
Operator Display 259
Operator Switch 260
Speed Input 260
Body-Up Switch 260
Brake Lock Switch 260
Payload Meter 260
Communications Ports 260
Key Switch Input 261
Payload Meter Power 261
Load Lights 261
Wiring and Termination 262
TCI Outputs 262
OPERATOR’S DISPLAY AND SWITCH 263
Reading the Speedometer 263
Reading the Load Display 263
Using the Operator ID 263
Using the Load and Ton Counter 263
Total Ton Counter 263
Total Load Counter 264
Clearing the Counters 264
Viewing Live Sensor Data 264
Other Display Messages 264
PAYLOAD OPERATION & CALCULATION 265
Description of Haul Cycle States 265
Haul Cycle Description 265
Load Calculation 266
Carry Back 266
Measurement Accuracy 266
SOURCES FOR PAYLOAD ERROR 266
Payload Error 266
Loading Conditions 267
Pressure Sensors 267
Swingloads 267
Speed and Distance 267
HAUL CYCLE DATA 267
Haul Cycle Warning Flags 269
Frame Torque Data 270
Sprung Weight Data 270
Maximum Speed Data 270
Alarm Records 270
Fault Code Data 271
PC SOFTWARE OVERVIEW 272
System Configuration 272
Installing the PLMIII Software 272
DOWNLOADING DATA 273
PLM III SYSTEM CONFIGURATION 274
Starting Communications 274
Displayed Payload Units 274
Time Units 274
Connection Menu 274
Connecting to the Payload Meter 275
Configure the Payload Meter 275
Setting the Date and Time 275
Setting the Truck Type 276
Setting the Gauge Display Units 276
Setting the Frame Serial Number 276
Setting the Truck Number 276
Setting the Komatsu Distributor 276
Setting the Komatsu Customer 276
Setting the Overload Speed Limit Function 277
Clean Truck Tare 278
Inclinometer Calibration 278
DATA ANALYSIS 279
Creating a Query 279
Sorting on Truck Unit Number 279
Sorting on Truck Type 279
Sorting on Date Range 280
Sorting on Time Range 280
Payload Detail Screen 281
Creating Reports 281
Summary – one page report 282
Detailed – multi-page report 282
Creating Graphs 283
Exporting Data 283
CSV Export 283
Compressed 284
Importing Data 285
Deleting Haul Cycle Records 285
Viewing Alarms 286
Deleting Alarm Records 286
TROUBLESHOOTING SECTION 287
TROUBLESHOOTING 287
Viewing Active Alarms 287
Real-Time Data Display 287
Testing the Payload Lights 287
Creating Log Files of Inputs 288
Daily Inspections 288
Periodic Maintenance 288
Abnormal Displays at Power-Up 289
No Payload Display When Key Switch is Turned ON 290
No Display on Speedometer 291
No Display on Operator Display 291
No Communications With PC 292
Load Lights Don’t Light During Loading 293
Load Lights Remain ON 294
Load Lights Remain ON During Dumping 294
Display Doesn’t Clear When The Load Is Dumped 294
Calibration Problems 295
Alarm 1 – Left Front Pressure High 296
Alarm 2 – Left Front Pressure Low 296
Troubleshoot Wiring to Left Front Suspension 296
Alarm 3 – Right Front Pressure High 297
Alarm 4 – Right Front Pressure Low 297
Troubleshoot Wiring to Right Front Suspension 297
Alarm 5 -Left Rear Pressure High 298
Alarm 6 – Left Rear Pressure Low 298
Troubleshoot Wiring to Left Rear Suspension 298
Alarm 7 – Right Rear Pressure High 299
Alarm 8 – Right Rear Pressure Low 299
Troubleshoot Wiring to Right Rear Suspension 299
Alarm 9 – Inclinometer High 300
Alarm 10 – Inclinometer Low 300
Troubleshoot Inclinometer Wiring 300
Alarm 13 – Body Up Input Failure 301
Alarm 16 – Memory Write Failure 302
Alarm 17 – Memory Read Failure 302
Alarm 18 302
Alarm 19 302
Alarm 22 302
Operator Switch Doesn’t Work 303
Alarm 26 – User Switch Fault – SELECT 303
Alarm 27 – User Switch Fault – SET 303
Connector Map 304
Connectors 305
PLMIII CHECK OUT PROCEDURE 306
General Description 306
Tools Required 306
Checkout Procedure 306
PLMIII CHECKOUT PROCEDURE CONFIRMATION 310
Flashburn Programming 310
Confirmation Checklist 312
SECTION E ELECTRICAL PROPULSION 313
SECTION E2 ELECTRICAL PROPULSION COMPONENTS INDEX 315
ELECTRICAL PROPULSION COMPONENTS 319
GENERAL SYSTEM DESCRIPTION 319
CONTROL SYSTEM 319
System Operation 320
FL275 Panel 321
CARD REPLACEMENT 322
Removal 322
Installation 322
Card Repair 322
Panel Wiring 322
COMPUTER DESCRIPTION 323
Microprocessor 323
Download Capability 323
SOFTWARE 323
Base Monitor Program 323
Runtime Monitor Program – OBJ Running Code 323
Configuration Software – CFG 324
PTU – Portable Test Unit Code 324
System Regulation 324
Propulsion 325
Retarding 325
TWO-DIGIT DISPLAY PANEL 326
The Coded Number 326
Events 326
Frames 327
Windows 327
System Categories 327
Limits On Resetting Faults 327
NA Faults 328
Event Sequence 328
Resetting Events 328
Event Descriptions 328
Subcode Descriptions 328
2-DIGIT DISPLAY PANEL SUBCODES 336
PORTABLE TEST UNIT (PTU) 339
DESCRIPTION 339
Operational Hints 339
SOFTWARE INSTALLATION PREPARATION 340
HARD DISK SPACE REQUIREMENTS 340
SOFTWARE INSTALLATION ON PTU 340
PTU/Truck Communication Problems 341
THE MAIN MENU 342
Quit Menu 342
PTU Talk To Truck 342
View PTU Saved Files 342
List Stat Data Files 342
Truck Setup (CFG) 342
Select Truck Setup 342
Update CFG Version 342
Change PTU Password 342
CONFIGURATION (CFG) FILE CONVERSION 344
Conversion Procedure 344
Convert Old CFG files for New software 345
STATEX CONFIGURATION FILES 348
0) Source Directory: 348
1) Select A Truck Configuration 349
2) View Truck Configuration: Data Curves 350
3) Change/View Serial and Model Numbers 351
4) View Options 351
5) Change/View Truck Specifics 353
6) Change/View Overspeeds 355
7) Save a Truck Configuration, filename: 356
8) Save Directory: 357
CHANGE PTU PASSWORD 358
PROGRAMMING THE TRUCK 359
Connect PTU to the Truck 359
Select Configuration File 359
Activate The PTU Mode 359
Check Object Code Version 360
Download Configuration Files 361
Date And Time 362
Event Data 363
Statistical Data 365
View Counters 365
View Profiles 365
Upload Statistical Data To A File 365
Statistical Data Codes – Counters 366
STATISTICAL DATA CODES – COUNTERS 367
STATISTICAL DATA CODES – PROFILES 372
TRUCK SPECIFIC INFORMATION 376
Temporary Truck Settings 377
MISCELLANEOUS FEATURES 378
Saving Data 378
PTU Abbreviations 379
Other Menu Selections 379
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 380
ALTERNATOR 380
ELECTRIC WHEEL MOTORS 380
RETARDING GRIDS 380
ELECTRONIC ACCELERATOR AND RETARD PEDALS 380
Removal 380
Installation 380
Disassembly 381
Reassembly 381
COOLING BLOWER WARNING SYSTEM 381
Operation 381
Test 381
Removal 382
Installation 382
ELECTRICAL CONTROL CABINET 383
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 388
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 389
SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX 391
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 395
GENERAL INFORMATION 395
COMMUNICATIONS PORT CHECK 396
PTU Hookup 396
4 0 SEQUENCE TESTS – (ENGINE NOT ON) 397
Preparation and Setup 397
CONTROL SYSTEM SELF-TEST 398
4 1 THROTTLE SYSTEM CHECK AND ADJUSTMENT 398
4 2 RETARD SYSTEM CHECK AND ADJUSTMENT 399
PTU Setup 399
4 3 REVERSER AND PROPULSION CONTACTORS CHECK 400
4 4 NOT USED 401
4 5 RETARD CONTACTORS OPERATION CHECK 401
4 6 GROUND FAULT SENSING CHECK 401
4 7 GROUND FAULT IN RETARD OPERATION CHECK 402
4 8 OVERRIDE OPERATION CHECK 402
4 9 ANTI-REVERSAL FUNCTION (AR) CHECK 403
4 10 OVERSPEED RETARD OPERATION CHECK 403
4 11 HOIST INTERLOCK OPERATION CHECK 404
4 12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK 404
Return to Main Menu 404
5 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 405
5 1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU 405
5 2 DIGITAL INPUT CHECKS 406
5 3 DIGITAL OUTPUT CHECKS 407
6 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 411
6 1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU 411
6 2 ANALOG INPUT CHECKS 412
6 3 FREQUENCY INPUT CHECKS 416
Return to Main Menu 417
7 0 SPEED EVENT CHECKS 417
Preparation and Setup 417
Setup PTU 417
7 1 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK 418
7 2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK 418
7 3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK 418
7 4 OTHER SPEED EVENTS CHECKS 418
Return to Main Menu 418
8 0 RETARD SPEED CONTROL SYSTEM CHECK 419
Preparation and Setup 419
Setup PTU 419
8 1 OVERSPEED PICKUP AND DROPOUT CHECK 419
8 2 RETARD POT MAXIMUM SETTING CHECK 419
8 3 RETARD POT MINIMUM SETTING CHECK 419
8 4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL 420
Return to Main Menu 420
9 0 LOAD TEST USING TRUCK RETARD GRIDS 420
Setup and Preparation 420
PTU Setup 420
9 1 LOAD TEST 421
10 0 MOTOR FIELD CURRENT CHECK IN RETARDING 421
Setup PTU 421
10 1 RETARD CHECK 422
11 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 423
11 1 BRAKE SYSTEM INTERLOCKS CHECK 423
Preparation 423
11 2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT 423
11 3 SYNC TRANSFORMER CHECKOUT 424
11 4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT 424
11 5 BATTERY BOOST ADJUSTMENT 424
11 6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST 424
11 7 MOTOR ROTATION TEST 425
11 8 GROUND FAULT CHECKS 425
12 0 MISCELLANEOUS CHARTS 426
12 1 WHEEL MOTOR GEAR RATIOS 426
12 2 MAXIMUM ALLOWABLE TRUCK SPEEDS 427
12 3 ENGINE 428
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS 429
SECTION G2 TIRES AND RIMS INDEX 431
TIRES AND RIMS 433
GENERAL INFORMATION 433
TIRES 433
Handling Tires 433
Tire Maintenance 434
Storing Tires After Removal 434
WHEEL STUD MAINTENANCE 435
REAR OUTER WHEEL STUD INSTALLATION 436
FRONT TIRES AND RIMS 437
Removal 437
Installation 438
REAR TIRES AND RIMS 439
Removal 439
Installation 440
RIM 441
Tire Removal 441
RIM AND TIRE PREPARATION 442
LUBRICANTS 442
TIRE INSTALLATION 443
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 445
FRONT WHEEL HUB AND SPINDLE 447
WHEEL HUB AND SPINDLE ASSEMBLY 447
Removal 447
Installation 449
Disassembly 450
Cleaning and Inspection 451
Assembly 451
Wheel Bearing Adjustment (Spindle Vertical) 454
Wheel Bearing Adjustment (Tire Mounted) 455
Spindle Removal Procedure (Optional) (off of the truck) 458
STEERING CYLINDERS AND TIE ROD 460
Spherical Bearing Wear Limits 460
Removal 461
Installation 463
Bearing Replacement 463
TOE-IN ADJUSTMENT 464
SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX 465
REAR AXLE HOUSING 467
PIVOT PIN 467
Removal 467
Installation 468
PIVOT EYE BEARING 468
Disassembly 468
Assembly 469
PIVOT EYE REPAIR 469
Removal 469
Disassembly 469
Bushing (New) 469
Pivot Eye Bore (New) 469
Assembly 469
Installation 470
ANTI-SWAY BAR 470
Removal 470
Installation 470
Disassembly 471
Cleaning and Inspection 471
Assembly 471
SECTION G5 REAR AXLE HOUSING INDEX 473
REAR AXLE HOUSING 475
REAR AXLE HOUSING 475
Removal 475
Installation 475
WHEEL MOTOR 475
Removal 475
Cleaning and Inspection 476
Installation 476
Maximum Cap Screw Usage 476
SECTION H SUSPENSIONS 479
SECTION H2 FRONT SUSPENSION INDEX 481
FRONT SUSPENSION 483
Removal 483
Installation 485
Angle Advance Tightening Procedure 486
Disassembly 487
Cleaning and Inspection 488
Assembly (Bearing Only) 488
Suspension Assembly (Complete) 488
SUSPENSION PRESSURE TEST 490
SECTION H3 REAR SUSPENSIONS INDEX 493
REAR SUSPENSIONS 495
Removal 496
Installation 498
Disassembly 498
Cleaning and Inspection 499
Assembly 499
SUSPENSION PRESSURE TEST 501
SECTION H4 OILING AND CHARGING PROCEDURES INDEX 503
OILING AND CHARGING PROCEDURE 505
GENERAL 505
EQUIPMENT LIST 505
Hydrair® Charging Kit 505
Installation of Charging Kit 505
Removal of Charging Kit 506
Support Blocks For Oiling and Charging Dimensions 506
FRONT SUSPENSION 507
Front Suspension Oiling 507
Front Suspension Nitrogen Charging 508
REAR SUSPENSION 510
Rear Suspension Oiling 510
Rear Suspension Nitrogen Charging 512
OIL AND NITROGEN SPECIFICATIONS CHART 513
SECTION J BRAKE CIRCUIT 515
SECTION J2 BRAKE CIRCUIT INDEX 517
BRAKE CIRCUIT 519
GENERAL DESCRIPTION 519
SERVICE BRAKE CIRCUIT 519
SECONDARY BRAKING AND AUTOMATIC APPLY 521
PARKING BRAKE CIRCUIT 521
Normal Operation (key switch on, engine on) 521
BRAKE LOCK CIRCUIT 522
WARNING CIRCUIT 522
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 525
BRAKE CIRCUIT COMPONENT SERVICE 527
BRAKE VALVE 527
Rebuild Criteria 527
Removal 527
Installation 529
Disassembly 531
Cleaning and Inspection 533
ASSEMBLY 533
Actuator Base Threaded Inserts 533
Boot and Cap 533
Valve Body Seal Installation 534
Regulator Sleeve O-Ring Installation 535
Actuator Plunger O-Ring Installation 535
Assembly of Valve 535
DIFFERENTIAL PRESSURE SWITCH 536
Disassembly 537
Cleaning and Inspection 537
Assembly 537
VALVE BENCH TEST AND ADJUSTMENT 537
Test Set Up Procedure 539
Brake Valve Output Pressure Adjustment 539
Differential Pressure Switch Test 540
Final Test and Adjustment 540
Installation Of Brake Pedal Actuator Assembly to Brake Valve 541
HYDRAULIC BRAKE ACCUMULATORS 543
Brake Accumulator Bleed-Down Procedure 543
Removal 543
Installation 545
Disassembly 545
Cleaning and Inspection 547
Assembly 547
Leak Testing 550
BRAKE ACCUMULATOR CHARGING 551
Temperature During Precharge 553
ACCUMULATOR STORAGE 553
Installation 554
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 555
BRAKE CIRCUIT CHECK-OUT PROCEDURE 557
EQUIPMENT REQUIRED 560
INITIAL SYSTEM SET-UP 561
Parking Brake 561
Service Brakes 562
Brake Lock/Secondary 562
Low Brake Pressure and Auto Apply 563
Reapplications 563
Differential Pressure Switch 563
The Brakes are Locked, Service, and/or Parking 565
Both Brake Circuits are Dragging 565
One Brake Circuit is Dragging 565
Brakes are Not Going to Full Pressure 565
A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off 565
Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released 566
Differential Pressure Warning Circuit is Not Operating 566
A Low Brake Pressure Warning Occurs When Brakes are Applied 566
Low Pressure Warning Circuit Not Operating Properly 566
Low Pressure Warning is On Even Though System Pressure is Correct 567
Low Pressure Warning Comes On and Pressure is Low 567
A Squeal is Heard When Controller is Operated 567
Output Pressure At Controller is Correct but Brakes are Not Applying 567
Brake Pressures Drift Excessively While Pedal is Held Steady 567
Oil is Leaking Around the Pedal Base 567
Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM 567
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 565
CHECK-OUT PROCEDURE 568
HYDRAULIC BRAKE SYSTEM DATA SHEET 568
SECTION J5 FRONT DISC BRAKES INDEX 571
FRONT DISC BRAKES 573
BRAKE CALIPER 573
Removal 573
Installation 574
Disassembly 575
Cleaning and Inspection 575
Assembly 577
BRAKE LINING 577
Replacement 577
FRONT SERVICE BRAKE BURNISHING 579
BRAKE BLEEDING PROCEDURE 580
SECTION J6 REAR BRAKES INDEX 581
REAR DISC BRAKES 583
REAR BRAKES 583
CALIPER, DISC, AND PARKING BRAKE 583
Removal 583
Installation 584
CALIPER PISTON 586
Piston Assembly Removal 586
Inspection 586
Piston Assembly Installation 587
FUNCTIONAL TEST OF PISTON ASSEMBLY 588
Return Spring Force 588
Built-In Clearance 588
Grip Force 590
Grip Force Measurement 591
Spring Force Measurement 593
Disassembly of Piston Assembly 594
Assembly of Piston Assembly 595
BENCH TEST 595
BRAKE LINING 596
Replacement 596
SERVICE BRAKE BURNISHING 599
SAFETY PRECAUTIONS 599
Rear Brake Burnishing 600
BRAKE BLEEDING PROCEDURE 601
Spring Force Measurement 602
SECTION J7 PARKING BRAKE INDEX 603
PARKING BRAKE 605
GENERAL INFORMATION 605
PARKING BRAKE CALIPER 605
Lining Thickness Inspection 605
Removal 606
Installation 606
Parking Brake Adjustment 607
Parking Brake Caliper Disassembly 608
Cleaning and Inspection 609
Parking Brake Caliper Assembly 610
PARKING BRAKE LINING REPLACEMENT 610
PARKING BRAKE BURNISH PROCEDURE 610
Lining Conditioning 610
BRAKE BLEEDING PROCEDURE 611
Hoist Circuit Operation 616
Steering, Brake and Pantograph Circuit Operation 616
Axle Blower System Operation 616
SECTION L HYDRAULIC SYSTEM 613
SECTION L2 HYDRAULIC SYSTEM INDEX 615
Hoist Circuit Operation 616
Steering, Brake and Pantograph Circuit Operation 616
Axle Blower System Operation 616
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 619
HYDRAULIC SYSTEM COMPONENT REPAIR 621
HOIST PUMP 621
Removal 621
Installation 623
Disassembly 623
Inspection 626
Assembly 627
PISTON PUMP 632
Removal 632
Installation 633
Disassembly 635
Inspection of Parts 641
Assembly 643
AXLE BLOWER HYDRAULIC MOTOR 648
Removal 648
Installation 648
Rear Axle Blower Housing 648
Disassembly 648
Assembly 649
Disassembly 651
Inspection 653
Assembly 654
Trouble Shooting 655
Hand Wheel Control 656
Disassembly 656
Assembly 656
HYDRAULIC TANK 658
Filling Instructions 658
Removal 659
Installation 659
HYDRAULIC TANK STRAINER AND DIFFUSER 660
Removal 660
Inspect and Clean 661
Installation 661
SECTION L4 STEERING CIRCUIT INDEX 663
STEERING CIRCUIT 665
STEERING CIRCUIT OPERATION 665
COMPONENT DESCRIPTION 666
Steering Control Valve 666
Unloader Valve 667
Bleed-Down Manifold Valve 667
Flow Amplifier 672
FLOW AMPLIFIER SYSTEM OPERATION 673
No Steer 673
Steering Left 675
Steering Right 677
No Steer, External Shock Load 679
Steering Pump 681
High Pressure Filter 681
Accumulators 681
Low Precharge Warning Switch 681
SECTION L5 STEERING CONTROL VALVE INDEX 683
STEERING CONTROL VALVE 685
Removal 685
Installation 686
STEERING CONTROL VALVE REBUILD 687
Disassembly 687
Cleaning and Inspection 688
Assembly 688
BRAKE / STEERING PUMP 692
Removal 692
Installation 694
Disassembly 695
Inspection of Parts 695
Assembly 697
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 699
STEERING CIRCUIT COMPONENT REPAIR 701
BLEED-DOWN MANIFOLD 701
Removal 701
Installation 701
ACCUMULATOR 702
Removal 702
Installation 703
Disassembly 704
Cleaning and Inspection 704
Assembly 705
Leak Testing 706
STEERING ACCUMULATOR CHARGING 707
Temperature During Precharge 710
ACCUMULATOR STORAGE 711
Installation 711
FLOW AMPLIFIER 712
Removal 712
Installation 712
Disassembly 713
Assembly 716
STEERING CYLINDERS 717
Disassembly 717
Piston Seal and Bearing Installation 717
Cylinder Assembly 717
Test 717
TROUBLESHOOTING CHART 720
SECTION L7 HOIST CIRCUIT INDEX 725
HOIST CIRCUIT 727
HOIST CIRCUIT OPERATION 727
COMPONENT DESCRIPTION 728
Hydraulic Tank 728
Hydraulic Pump 728
High Pressure Filter 728
Hoist Valve 728
Hoist Pilot Valve 729
Bleed-Down Manifold 730
Counterbalance Manifold 730
Hoist-Up Limit Solenoid 730
Pilot Operated Check Valve 730
HOIST VALVE OPERATION 732
Float Operation 732
Power Up Operation (Figure 7-6) 734
Hold Operation (Figure 7-7) 736
Power Down Operation (Figure 7-8) 738
Float Operation (Figure 7-9) 740
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 743
HOIST CIRCUIT COMPONENT REPAIR 745
HOIST VALVE 745
Removal 745
Installation 745
O-Ring Replacement 747
INLET SECTION 748
Disassembly 748
Cleaning and Inspection 749
Assembly 749
REAR SPOOL SECTION (WORK PORTS) 750
Disassembly 750
Cleaning and Inspection 752
Assembly 752
HOIST PILOT VALVE 754
Removal 754
Installation 754
Disassembly 755
Cleaning and Inspection 756
Assembly 756
HOIST UP LIMIT SOLENOID VALVE 757
HOIST CYLINDERS 758
Removal 758
Installation 759
Disassembly 761
Cleaning and Inspection 762
SS1143 Tightening Tool – Assembly Drawing 763
ASSEMBLY OF QUILL AND CYLINDER 763
Quill Installation 763
Installation Of Check Balls And Plugs In Quill 764
Assembly of Cylinder 766
Pressure Testing 767
COUNTERBALANCE MANIFOLD 767
SECTION L9 HIGH PRESSURE FILTERS INDEX 769
HYDRAULIC SYSTEM FILTERS 771
HOIST CIRCUIT FILTER 771
Filter Element Replacement 771
Removal 772
Installation 772
Indicator Switch 772
STEERING CIRCUIT FILTER 773
Filter Element Replacement 773
Removal 774
Installation 774
Indicator Switch 774
INDICATOR SWITCH 774
Test Procedure 774
SECTION L10 HYDRAULIC CHECK-OUT PROCEDURE INDEX 777
HYDRAULIC CHECK-OUT PROCEDURE 779
INITIAL START UP AND FLUSHING 779
COMPONENT CHECKOUT AND ADJUSTMENT 781
ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE 783
Counterbalance Valve Adjustment 785
Manifold Assembly 785
OIL CLEANLINESS CHECK 785
Oil Sampling Location On Truck 785
Oil Sampling Process and Cleanliness Criteria 786
DISABLED TRUCK DUMPING PROCEDURE 786
Hookup 786
Raising the Body 786
Lowering the Body 787
TROUBLESHOOTING CHART 788
Hoist Pump 788
Steering Circuit 790
Brake/Steering Pump 792
Flow Amplifier – Refer to Figure 10-9 794
SECTION M OPTIONS AND SPECIAL TOOLS 795
SECTION M4 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM INDEX 797
ELECTRIC DRIVE COOLING AIR FILTER SYSTEM 799
SYSTEM ADJUSTMENT 799
PUMP 802
Removal 802
Disassembly 802
Inspection 802
Assembly 802
Installation 802
BLOWER DRIVE MOTOR 805
Removal 805
Disassembly 805
Inspection Of Parts 806
Assembly 807
Installation 808
BLOWER BEARING REPAIR 808
Removal 808
Replacement 808
Assembly 809
AIR CLEANER 809
Assembly 809
Removal 809
Assembly 809
SECTION M7 HEATER OPTIONS INDEX 811
ENGINE OIL HEATERS 813
GENERAL INFORMATION 813
TROUBLESHOOTING 813
HEATER ELEMENT 814
Removal 814
Installation 814
GENERAL 815
Maintenance 815
HEATING ELEMENT 815
Removal 815
Installation 816
THERMOSTAT 816
Removal 816
Installation 816
HYDRAULIC OIL HEATERS 817
GENERAL INFORMATION 817
TROUBLESHOOTING 817
HEATER ELEMENT 818
Removal 818
Installation 818
SECTION M8 SPECIAL TOOLS INDEX 819
NITROGEN CHARGING VALVE 819
ROLL-OUT ASSEMBLY 819
EYE BOLT 819
OFFSET WRENCH 820
TORQUE ADAPTER 820
HANDLE 820
SEAL INSTALLER 820
SLEEVE ALIGNMENT TOOLS 821
QUICK DISCONNECT COUPLING 821
HARNESS 821
SEAL INSTALLATION RING 821
BELT TENSION TESTER 822
BELT ALIGNMENT TOOL 822
SOCKETS AND ADAPTERS 822
DUST CAPS 822
HYDRAULIC SYSTEM FLUSHING TOOLS 823
PAYLOAD DATA MANAGER 823
HYDRAULIC SYSTEM VACUUM PUMP 823
MISCELLANEOUS SERVICE TOOLS 824
HIGH VOLTAGE TOOLS 827
2000 VDC METER 827
GROUNDING STICKS 827
BODY PAD SPACER TOOL 828
SECTION M19 RADIATOR SHUTTERS INDEX 829
RADIATOR SHUTTERS 831
OPERATION 831
Hydraulic Circuit 831
Electrical Circuit: 832
MAINTENANCE AND REPAIR 832
TROUBLESHOOTING 833
Hydraulic Troubleshooting 836
Electrical Troubleshooting 838
SECTION N OPERATOR’S CAB 839
SECTION N2 TRUCK CAB INDEX 841
TRUCK CAB 843
TRUCK CAB 843
Description 843
Removal 844
Installation 846
CAB DOOR 846
Removal 846
Installation 847
Door Adjustment 847
Door Jam Bolt Adjustment 847
Door Handle Plunger Adjustment 849
Replace Door Glass 850
Replace Door Window Regulator 854
Replace Door Handle or Latch Assembly 854
Door and Door Hinge Seal Replacement 855
Door Opening Seal Removal 855
Installation 855
GLASS REPLACEMENT 856
Adhesive-Bonded Windows 856
Recommended Tools/Supplies 856
Replacement Procedure 856
Windshield and Rear Glass 857
Removal 857
Installation 858
REMOVAL AND INSTALLATION OF OPERATOR SEAT 859
Inspection 859
Removal 859
Installation 859
REMOVAL AND INSTALLATION OF PASSENGER SEAT 860
Removal 860
Installation 860
SECTION N3 CAB COMPONENTS INDEX 861
WINDSHIELD WIPERS 863
WIPER MOTOR REPLACEMENT 863
Removal 863
Installation 863
WIPER ARM REPLACEMENT 863
Removal 863
Installation 864
WIPER LINKAGE REPLACEMENT 864
Removal 864
Installation 865
WINDSHIELD WASHER 865
Operation 865
Service 865
SEAT BELT 866
Removal 866
Installation 866
SECTION N4 OPERATOR COMFORT INDEX 869
OPERATOR COMFORT 871
HEATER / AIR CONDITIONER 871
Fan Speed Control Knob 871
Temperature Control Knob 871
Air Flow Directional Knob 871
Heater/Air Conditioner Vents 872
COMPONENTS 872
Fuse and Circuit Breaker 872
Relays 872
Heater Core 872
Fan Motor And Speed Control 873
Actuators 873
Cab Air Filter 873
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 876
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 876
PRINCIPLES OF REFRIGERATION 876
Air Conditioning 876
Refrigeration – The Act Of Cooling 877
The Refrigeration Cycle 877
AIR CONDITIONER SYSTEM COMPONENTS 878
Compressor (Refrigerant Pump) 878
Service Valves 878
Condenser 878
Receiver-Drier 878
Expansion Block Valve 879
Accumulator 879
Evaporator 879
ELECTRICAL CIRCUIT 880
Thermostat 880
Compressor Clutch 880
Trinary™ Switch 881
SYSTEM SERVICING 882
SERVICE TOOLS AND EQUIPMENT 883
Recovery/Recycle Station 883
Leak Detector 883
Service Valves 884
Vacuum Pump 884
Manifold Gauge Set 885
Installing Manifold Gauge Set 886
Purging Air From Service Hoses 886
SYSTEM PERFORMANCE TEST 887
SYSTEM OIL 888
Handling and Reusing PAG Oil 888
Oil Quantity 888
Checking System Oil 888
REFRIGERANT 889
Recycled Refrigerant 889
Reclaimed Refrigerant 889
Refrigerant Quantity 889
R-134a Refrigerant Containers 890
SYSTEM LEAK TESTING 890
Electronic Leak Detector 891
Tracer Dyes 891
Soap and Water 891
RECOVERING AND RECYCLING THE REFRIGERANT 891
Draining Oil from the Previous Recovery Cycle 891
Performing the Recovery Cycle 891
Performing the Recycling Procedure 892
Evacuating and Charging the A/C System 892
SYSTEM REPAIR 892
System Flushing 892
A/C DRIVE BELT CHECKOUT PROCEDURE 893
Pulley Alignment 893
Belt Tension Check 893
COMPONENT REPLACEMENT 895
Hoses and Fittings 895
Lines 895
Expansion Valve 895
Receiver-Drier 895
Thermostat 895
Compressor 896
Accumulator 896
Clutch 896
Servicing the Compressor Clutch 897
Pulley Removal 899
Clutch Coil Check 900
Pulley Installation 900
Clutch Assembly Installation 900
EVACUATING THE SYSTEM 902
CHARGING THE A/C SYSTEM 904
TROUBLESHOOTING 905
Preliminary Checks 905
Diagnosis Of Gauge Readings And System Performance 905
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 906
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 912
SECTION N5 OPERATOR CONTROLS AND EQUIPMENT INDEX 913
OPERATOR CAB AND CONTROLS 915
STEERING WHEEL AND CONTROLS 916
HORN BUTTON 916
TILT/TELESCOPE LEVER 916
MULTI-FUNCTION TURN SIGNAL SWITCH 916
Turn Signal Operation 916
High Beam Headlight Operation 916
Windshield Wiper Operation 916
STEERING COLUMN 917
Removal 917
Inspection 917
Installation 918
STEERING WHEEL 918
Removal 918
Installation 918
PEDALS 920
SERVICE BRAKE PEDAL 920
DYNAMIC RETARDER PEDAL 920
Optional – Dual Function/Single Pedal 920
THROTTLE PEDAL 920
GRADE/SPEED WARNING CHART 921
OVERHEAD PANEL CONTROLS AND COMPONENTS 921
RADIO SPEAKERS 921
WARNING ALARM BUZZER 921
CAB RADIO 921
WARNING LIGHTS DIMMER CONTROL 921
WARNING/STATUS INDICATOR LIGHT PANEL 921
AIR CLEANER VACUUM GAUGES 921
WINDSHIELD WIPERS 921
CENTER CONSOLE 922
TRUCK CONTROLS 922
F-N-R Selector Switch 922
Hoist Control Lever 923
CONSOLE SWITCHES AND CONTROLS 923
Ashtray 923
Cigarette Lighter 923
Left-Hand Window Control Switch 923
Right-Hand Window Control Switch 923
Engine Shutdown Switch 923
Override Switch 923
Retard Speed Control (RSC) Switch 924
Retard Speed Control (RSC) Dial 924
Statex III Download Port 925
Engine Diagnostic Port (CENSE) 925
Modular Mining Port 925
Passenger Seat 925
Engine Diagnostic Connectors 925
Engine Diagnostics Connector 925
Data Store Button 925
PAYLOAD METER 925
Payload Meter Download Connector 925
OPERATOR’S SEAT 926
Seat Belts 926
Adjustment 926
INSTRUMENT PANEL 927
CONTROL SYMBOLS 927
CONTROL SWITCHES AND GAUGES 928
Key Switch 928
Engine Shutdown Switch With Timer Delay 929
Fog Light Switch 929
Ladder Light Switch 929
Backup Light Switch 929
Panel Illumination Lights 929
Cab Air Conditioner/Heater Vents 929
Engine Cold Weather Starting Aid Switch 929
Rotating Beacon Light Switch 929
Heated Mirror Switch 929
Wheel Brake Lock Switch 930
Parking Brake Switch 930
Digital Tachometer 930
Right Turn Signal Indicator Light 931
High Beam Headlight Indicator Light 931
Left Turn Signal Indicator Light 931
Digital Speedometer/Payload Meter Display 931
Voltmeter Gauge 931
Engine Oil Pressure Gauge 931
Engine Water Temperature Gauge 931
Fuel Gauge 931
Engine Hourmeter 931
Headlight Switch 932
Panel Illumination Lights Dimmer Rheostat 932
Payload Meter Switch 932
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL 933
DESCRIPTION OF INDICATOR SYMBOLS 933
INDICATOR LIGHT FUNCTIONS 934
A1 High Hydraulic Oil Temperature 934
B1 Low Steering Pressure 934
C1 Low Accumulator Precharge Pressure 935
D1 Electric System Fault 935
E1 Low Brake Pressure 935
A2 Low Hydraulic Tank Level 935
B2 Automatic Lubrication System Pressure 935
C2 Circuit Breaker Tripped 935
D2 Hydraulic Oil Filter Monitor 936
E2 Low Fuel 936
A3 Parking Brake 936
B3 Service Brake 936
C3 Body Up 936
D3 Dynamic Retarding 936
E3 Stop Engine 936
A4 Not Used 937
B4 Manual Backup Lights 937
C4 Engine Shutdown Timer 937
D4 Retard Speed Control (RSC) 937
E4 Check Engine 937
A5 Service Engine Indicator (AEM) 937
B5 High Wheel Motor Temperature 937
C5 Blower Fault 937
D5, E5, A6, B6, and C6 Not Used 937
D6 Service Engine (CENSE) 937
E6 Not Used 937
Komatsu Engines w/Centry™ Fuel Control 938
Hazard Warning Light Switch 938
Lamp Test Switch/Centry™ Diagnostic Test Switch 938
TROLLEY INDICATOR LIGHTS 938
A7 Diesel Power Indicator 938
B7 Ready For Trolley Indicator 938
C7 On Trolley Indicator 938
D7 Trolley Fault Indicator 939
E7 Left Limit Indicator (Optional) 939
A8 Max Speed Indicator 939
B8 High Speed Indicator 939
C8 Med Speed Indicator 940
D8 Low Speed Indicator 940
E8 Right Limit Indicator (Optional) 940
REAR AXLE LIGHT BAR 941
Backup Lights 941
Retard Lights 941
Brake Light 941
Backup Alarm 941
CENTRY™ FUEL SYSTEM DIAGNOSTICS 942
GENERAL OPERATION 942
DETERMINING FAULT CODES 942
EXITING THE DIAGNOSTICS MODE 943
SECTION P LUBRICATION AND SERVICE 945
SECTION P2 LUBRICATION AND SERVICE INDEX 947
LUBRICATION AND SERVICE 949
GENERAL INFORMATION 949
HYDRAULIC TANK SERVICE 949
Adding Oil 949
COOLANT LEVEL CHECK 950
Radiator Filling Procedure 950
Coolant Specifications 950
Unacceptable Practices 950
WHEEL MOTOR SERVICE 950
RESERVE ENGINE OIL SYSTEM (Optional) 951
Reserve Oil Tank Filling Procedure (Remote fill) 951
Inline Screen 951
QUICK FILL SERVICE CENTER 952
LUBRICATION CHART 953
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS 954
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued) 955
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 956
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 956
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 957
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 958
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 959
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 960
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 961
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS 962
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS 962
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 963
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS 964
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 965
GENERAL DESCRIPTION 967
SYSTEM COMPONENTS 968
Filter Assembly 968
Hydraulic Motor and Grease Pump 968
Reservoir 968
Fixed Pressure Reducing Valve 968
Flow Control Valve 968
Solenoid Valve 969
Vent Valve 969
24VDC Lubrication Cycle Timer 969
Time Delay Module 969
Pump Cutoff Pressure Switch 969
Unloader Valve 969
Pressure Switch 969
Manual Override Button 969
Injectors 969
SYSTEM OPERATION 972
Normal Operation 972
Pressure Failure Detection Circuits 973
GENERAL INSTRUCTIONS 974
LUBRICANT REQUIRED FOR SYSTEM 974
SYSTEM PRIMING 974
LUBRICANT PUMP 975
Pump Housing Oil Level 975
Pump Pressure Control 975
FILTER AND RESERVOIR 975
Filter Assembly Element 976
INJECTORS (SL-1 Series H) 976
Injector Specifications 976
Injector Adjustment 976
INJECTOR OPERATION 978
SYSTEM CHECKOUT 979
Lubrication Cycle Timer Check 979
Lubrication Cycle Timer Adjustment 980
PREVENTIVE MAINTENANCE INSPECTION 980
10 Hour Lubrication System Inspection 980
100 Hour Inspection 980
250 Hour Inspection 980
500 Hour Inspection 981
1000 Hour Inspection 981
PUMP REBUILD 982
Disassembly 982
Cleaning and Inspection 982
Assembly 984
VENT VALVE REBUILD 985
Disassembly and Assembly 985
SYSTEM TROUBLESHOOTING CHART 986
SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX 989
MOTORIZED WHEEL MAINTENANCE SCHEDULE 991
AXLE BOX 991
MOTORIZED WHEEL MAINTENANCE SCHEDULE 992
ARMATURE AREA 992
AT TIRE CHANGE 992
MOTORIZED WHEEL MAINTENANCE SCHEDULE 993
GENERATOR/ALTERNATOR 993
GRID BLOWER MOTOR 993
CONTROL EQUIPMENT CHECKS 993
MOTORIZED WHEEL MAINTENANCE SCHEDULE 994
VEHICLE OPERATIONS TESTS 994
SECTION R SYSTEM SCHEMATICS 995

DESCRIPTION:

Komatsu 730E DUMP TRUCK – TROLLEY Shop Manual CEBM025001 – PDF DOWNLOAD

• SERIAL NUMBERS    730E A30617 and up
  ENGINE                       16V159

• FOREWORD:
• This manual is written for use by the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
• All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service, and reassembly.
• Each major serviceable component has a section in the shop manual. Disassembly of any component should only be done as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
• This manual shows dimensioning in metric units and in U.S. English units. All references to Right, Left, Front, or Rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements for common fasteners are shown in torque charts in the general information section. Special torque requirtements are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
• A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating. The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E).
• The three numbers represent the basic truck model. The letter E, when present, designates an electrical wheel motor drive system. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
• This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload. To determine allowable payload, fill all lubricants and fuel tank to the proper level. Weigh the truck and record this value. Subtract it from the GVW to determine the allowable payload.

G.B 18/12/24