Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30403 & A30406) – PDF Download
Original price was: $82.95.$26.95Current price is: $26.95.
- KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL
- Serial Number: A30403 & A30406
- Publication Number:CEBM018200
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30403 & A30406)
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30403 & A30406) – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30403 & A30406)
- This manual is written for use by the operator and/or the service technician and 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 understand the content in this manual before maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before repairing the truck.
- This manual shows dimensioning of metric and (U.S. standard) units throughout. 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 are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lbs).
- All torque specifications have ±10% tolerance unless otherwise specified. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. 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 Gross Vehicle Weight (GVW) rating.
- 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 GVW. GVW is the total truck weight. This is equal to the empty vehicle weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty truck. This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating. The result is the allowable payload.
TABLE OF CONTENTS:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN: A30403 & A30406)
MAIN MENU........................................................................................................ 0 COVER............................................................................................................ 1 FOREWORD......................................................................................................... 5 TABLE OF CONTENTS................................................................................................ 7 SECTION A - GENERAL INFORMATION - INDEX.......................................................................... 9 SECTION A2 - MAJOR COMPONENT DESCRIPTION..................................................................... 11 SECTION A3 - GENERAL SAFETY AND OPERATION - INDEX............................................................ 15 GENERAL SAFETY........................................................................................... 17 PERSONAL SAFETY...................................................................................... 17 Safety Rules..................................................................................... 17 Truck Safety Features............................................................................ 17 Clothing And Personal Items...................................................................... 17 Unauthorized Modification........................................................................ 17 Leaving The Operator’s Seat...................................................................... 17 Mounting And Dismounting......................................................................... 18 Fire Extinguishers And First Aid Kits............................................................ 18 Precautions For High Temperature Fluids.......................................................... 18 Asbestos Dust Hazard Prevention.................................................................. 18 Fire Prevention For Fuel And Oil................................................................. 19 ROPS Precautions................................................................................. 19 Preventing Injury From Work Equipment............................................................ 19 Precautions For Optional Attachments............................................................. 19 Precautions When Starting The Machine............................................................ 19 PRECAUTIONS FOR TRUCK OPERATION...................................................................... 20 Safety Is Thinking Ahead......................................................................... 20 Safety At The Work Site.......................................................................... 20 Fire Prevention.................................................................................. 20 Preparing For Operation.......................................................................... 20 Ventilation For Enclosed Areas................................................................... 20 Mirrors, Windows, And Lights..................................................................... 21 In The Operator’s Cab - Before Starting The Engine............................................... 21 OPERATING THE MACHINE................................................................................ 21 Starting The Engine.............................................................................. 21 Truck Operation - General........................................................................ 21 Traveling In The Truck........................................................................... 22 Precautions When Traveling In Reverse............................................................ 22 Traveling On Slopes.............................................................................. 23 Ensuring Good Visibility......................................................................... 23 Operating On Snow................................................................................ 23 Avoid Damage To The Dump Body.................................................................... 23 Driving Near High-Voltage Cables................................................................. 23 When Loading The Truck........................................................................... 24 When Dumping..................................................................................... 24 Working On Loose Ground.......................................................................... 24 Parking The Machine.............................................................................. 24 TOWING............................................................................................... 24 WORKING NEAR BATTERIES............................................................................... 25 Battery Hazard Prevention........................................................................ 25 Jump-Starting With Booster Cables................................................................ 25 MAINTENANCE PRECAUTIONS.............................................................................. 25 BEFORE PERFORMING MAINTENANCE.................................................................... 25 Stopping The Engine Before Service........................................................... 25 Warning Tag.................................................................................. 26 Proper Tools................................................................................. 26 Securing The Dump Body....................................................................... 26 DURING MAINTENANCE............................................................................... 27 Personnel.................................................................................... 27 Attachments.................................................................................. 27 Working Under The Machine.................................................................... 27 Keeping The Machine Clean.................................................................... 27 Adding Fuel Or Oil........................................................................... 27 Radiator Coolant Level....................................................................... 27 Use Of Lighting.............................................................................. 28 Precautions With The Battery................................................................. 28 Handling High-Pressure Hoses................................................................. 28 Precautions With High-Pressure Oil........................................................... 28 Maintenance Near High Temperatures And High Pressures........................................ 28 Rotating Fan And Belts....................................................................... 28 Waste Materials.............................................................................. 28 TIRES............................................................................................ 29 Handling Tires............................................................................... 29 Tire Maintenance............................................................................. 29 Storing Tires After Removal.................................................................. 30 ADDITIONAL JOB SITE RULES................................................................................ 31 WHEN REPAIRS ARE NECESSARY............................................................................... 32 OPERATING INSTRUCTIONS................................................................................... 33 PREPARING FOR OPERATION.............................................................................. 33 SAFETY IS THINKING AHEAD............................................................................. 33 WALK-AROUND INSPECTION............................................................................... 33 ENGINE START-UP...................................................................................... 37 AFTER THE ENGINE HAS STARTED......................................................................... 38 MACHINE OPERATION SAFETY PRECAUTIONS................................................................. 39 LOADING.............................................................................................. 39 HAULING.............................................................................................. 40 PASSING.............................................................................................. 40 DUMPING.............................................................................................. 41 To Raise The Dump Body:.......................................................................... 41 To Lower The Dump Body: (When dumping over a berm or into a crusher):............................ 42 To Lower The Dump Body (When dumping on flat ground):............................................ 42 TOWING............................................................................................... 43 SAFE PARKING PROCEDURES.............................................................................. 43 ENGINE SHUTDOWN PROCEDURE............................................................................ 44 DELAYED ENGINE SHUTDOWN PROCEDURE.................................................................... 44 SUDDEN LOSS OF POWER................................................................................. 45 EMERGENCY STEERING SYSTEM............................................................................ 45 Operation........................................................................................ 45 Testing.......................................................................................... 46 TROLLEY OPERATING INSTRUCTIONS....................................................................... 46 AFTER THE ENGINE HAS STARTED..................................................................... 46 OPERATING IN DIESEL MODE......................................................................... 47 OPERATING IN TROLLEY LINE MODE................................................................... 47 GETTING ON LINE.................................................................................. 48 Operating On Trolley......................................................................... 50 GETTING OFF LINE................................................................................. 51 LINE STATUS SIGNALS.............................................................................. 51 LINE STATUS SIGNAL MARKINGS...................................................................... 52 TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION................................................. 52 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK..................................... 53 OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS........................................... 53 TRUCK FAILURE WHILE ON TROLLEY................................................................... 53 SECTION A4 - WARNINGS AND CAUTIONS........................................................................... 55 SECTION A5 -STANDARD TORQUE CHARTS AND CONVERSION TABLES..................................................... 63 SECTION A7 - STORAGE AND IDLE MACHINE PREPARATION - INDEX.................................................... 69 STORAGE AND IDLE MACHINE PREPARATION..................................................................... 71 SHORT TERM IDLE PERIODS.............................................................................. 71 PREPARATION FOR STORAGE.............................................................................. 72 REMOVAL FROM STORAGE................................................................................. 73 RECONDITIONING AN IDLE VEHICLE....................................................................... 74 ENGINE OPERATION..................................................................................... 77 After The Engine Has Started..................................................................... 77 ENGINE STORAGE....................................................................................... 78 Temporary Storage (30 Days Or Less).............................................................. 78 Extended Storage (More Than 30 Days)............................................................. 79 RESTORING AN ENGINE AFTER EXTENDED STORAGE........................................................... 80 ELECTRIC DRIVE TRUCKS................................................................................ 81 Storing A Truck That Is Operational.............................................................. 81 Storing A Truck That Is Not Operational.......................................................... 82 Storing A Major Component........................................................................ 83 Periodic Inspections............................................................................. 83 Placing Equipment Into Service After Storage..................................................... 83 SECTION B - STRUCTURES - INDEX................................................................................... 85 SECTION B2 - STRUCTURAL COMPONENTS - INDEX................................................................... 87 STRUCTURAL COMPONENTS.................................................................................... 89 LADDERS.............................................................................................. 89 Removal.......................................................................................... 89 Installation..................................................................................... 89 GRILLE AND HOOD...................................................................................... 90 Removal.......................................................................................... 90 Installation..................................................................................... 90 RIGHT-HAND DECK...................................................................................... 90 Removal.......................................................................................... 90 Installation..................................................................................... 92 CENTER DECK.......................................................................................... 92 LEFT-HAND DECK....................................................................................... 93 Removal.......................................................................................... 93 Installation..................................................................................... 93 SECTION B3 - DUMP BODY - INDEX............................................................................... 95 DUMP BODY................................................................................................ 97 DUMP BODY............................................................................................ 97 Removal.......................................................................................... 97 Installation..................................................................................... 98 BODY SLING........................................................................................... 98 BODY PADS............................................................................................ 99 Adjustment....................................................................................... 99 BODY GUIDE........................................................................................... 100 BODY POSITION INDICATOR.............................................................................. 100 HOIST LIMIT SWITCH................................................................................... 100 ROCK EJECTORS........................................................................................ 100 Inspection....................................................................................... 100 SECTION B4 - FUEL TANK - INDEX............................................................................... 101 FUEL TANK................................................................................................ 103 Removal.............................................................................................. 103 Repair............................................................................................... 103 Cleaning............................................................................................. 103 Installation......................................................................................... 104 FUEL GAUGE SENDER........................................................................................ 105 Removal.............................................................................................. 105 Installation......................................................................................... 105 LOW FUEL SENDER.......................................................................................... 106 Removal.............................................................................................. 106 Installation......................................................................................... 106 FUEL RECEIVER............................................................................................ 107 TANK BREATHER VALVE...................................................................................... 108 Removal.............................................................................................. 108 Installation......................................................................................... 108 Disassembly.......................................................................................... 108 Assembly............................................................................................. 108 SECTION C - ENGINE - INDEX....................................................................................... 109 SECTION C2 - POWER MODULE - INDEX............................................................................ 111 POWER MODULE............................................................................................. 113 GENERAL INFORMATION.................................................................................. 113 POWER MODULE SERVICE................................................................................. 114 Removal.......................................................................................... 114 Installation..................................................................................... 118 SECTION C3 - COOLING SYSTEM - INDEX.......................................................................... 121 COOLING SYSTEM........................................................................................... 123 RADIATOR............................................................................................. 123 Removal.......................................................................................... 123 Service.......................................................................................... 124 Installation..................................................................................... 124 RADIATOR FILL PROCEDURE.......................................................................... 125 RADIATOR REPAIR.................................................................................. 125 Internal Inspection.......................................................................... 125 External Cleaning............................................................................ 126 Disassembly.................................................................................. 126 Cleaning and Inspection...................................................................... 127 Assembly..................................................................................... 127 Additional Service Information............................................................... 129 PRESSURE TESTING................................................................................. 129 COOLANT SYSTEM TROUBLESHOOTING................................................................... 129 SECTION C4 - POWER TRAIN - INDEX............................................................................. 131 POWER TRAIN.............................................................................................. 133 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE........................................................ 133 General Information.............................................................................. 133 Removal.......................................................................................... 133 ALTERNATOR INSTALLATION.............................................................................. 135 Engine/Alternator Mating......................................................................... 135 Alternator Measurement........................................................................... 135 Engine End Play Measurement...................................................................... 136 Determining Shim Requirements.................................................................... 137 Installing Alternator On Engine.................................................................. 138 ENGINE............................................................................................... 139 Removal.......................................................................................... 139 Installation..................................................................................... 139 SECTION C5 - AIR CLEANERS - INDEX............................................................................ 141 AIR CLEANERS............................................................................................. 143 Service Checks....................................................................................... 143 Filter Element Replacement........................................................................... 144 Main Filter Element Cleaning......................................................................... 146 Precleaner Section................................................................................... 147 Cleaning Precleaner Tubes............................................................................ 147 Air Intake Troubleshooting........................................................................... 148 SECTION C7 - FAN DRIVE CLUTCH - INDEX........................................................................ 149 FAN DRIVE CLUTCH......................................................................................... 151 GENERAL DESCRIPTION.................................................................................. 151 COMPONENTS........................................................................................... 151 Input............................................................................................ 151 Output........................................................................................... 151 Stationary Components............................................................................ 152 OPERATION MODES...................................................................................... 153 Fully Engaged.................................................................................... 153 Modulated Variable Speed......................................................................... 153 Fully Released................................................................................... 154 Remember:........................................................................................ 154 Lubricating and Cooling Oil...................................................................... 155 MAINTENANCE.......................................................................................... 156 Maintenance Checks To Be Made.................................................................... 156 TROUBLESHOOTING...................................................................................... 157 Basic Preliminary Checks......................................................................... 157 FIELD CHECK DIAGNOSIS................................................................................ 158 Preliminary Checks With Engine Off............................................................... 158 Check Clutch Release............................................................................. 158 Check Clutch Lock-up............................................................................. 159 Overheating Complaint............................................................................ 160 Thermal Sensor and Solenoid Valve................................................................ 160 On Truck Test.................................................................................... 160 Off Truck Test................................................................................... 161 Test Conditions and Requirements:................................................................ 161 Test:............................................................................................ 161 TROUBLESHOOTING CHART.................................................................................... 162 FAN CLUTCH DISASSEMBLY INSTRUCTIONS...................................................................... 165 REASSEMBLY OF THE FAN CLUTCH............................................................................. 172 INSPECTION OF PARTS...................................................................................... 183 REBUILD TOOLS............................................................................................ 186 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX..................................................... 189 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX............................................................ 191 24VDC ELECTRIC SUPPLY SYSTEM............................................................................. 193 ELECTRICAL SYSTEM DESCRIPTION........................................................................ 193 BATTERIES............................................................................................ 193 Maintenance and Service.......................................................................... 193 Troubleshooting.................................................................................. 193 BATTERY CHARGING ALTERNATOR.......................................................................... 195 24VDC ELECTRIC START SYSTEM.......................................................................... 195 CRANKING MOTORS.................................................................................. 195 Removal...................................................................................... 195 Installation................................................................................. 196 CRANKING MOTOR TROUBLESHOOTING................................................................... 196 Preliminary Inspection....................................................................... 197 No-Load Test................................................................................. 197 Interpreting Results of Tests................................................................ 197 Disassembly.................................................................................. 198 Cleaning and Inspection...................................................................... 198 Armature Servicing........................................................................... 198 Field Coil Checks............................................................................ 201 Field Coil Removal........................................................................... 201 Solenoid Checks.............................................................................. 201 Test......................................................................................... 201 Assembly..................................................................................... 202 Pinion Clearance............................................................................. 203 MAGNETIC SWITCH.................................................................................. 204 Coil Test.................................................................................... 204 Electric Start System Wiring Diagrams........................................................ 204 ENGINE PRELUB SYSTEM................................................................................. 204 OPERATION........................................................................................ 204 Pressure Switch.............................................................................. 205 Suction Line................................................................................. 205 Outlet Line.................................................................................. 205 Check Valve.................................................................................. 205 Solenoid Timer............................................................................... 205 TROUBLESHOOTING PRELUB STARTER CIRCUIT................................................................... 207 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX...................................................... 211 24VDC ELECTRICAL SYSTEM COMPONENTS....................................................................... 213 PASSENGER SEAT BASE COMPARTMENT...................................................................... 213 COMPONENTS........................................................................................... 213 Taillight Resistor Diode Assemblies.............................................................. 213 Inclinometer..................................................................................... 213 Brake Warning Buzzer (BWB)....................................................................... 213 Lubrication System Timer......................................................................... 213 Five Minute Idle Timer Components................................................................ 213 Five Minute Idle Timer........................................................................... 215 Five Minute Idle Relay........................................................................... 215 Five Minute Idle Contactor....................................................................... 215 Five Minute Idle Circuit Test.................................................................... 215 Data Store Switch................................................................................ 215 Komatsu Engine Quantum Connector (Not Used)...................................................... 215 Komatsu Engine Cense Connector................................................................... 215 STATEX III Propulsion System Diagnostic Connector................................................ 215 Spare Connector Location......................................................................... 215 Alarm Indicating Device (AID) System............................................................. 216 Diode Matrix (Without Sound)..................................................................... 216 Diode Matrix (With Sound)........................................................................ 217 Hot Switch Inverter.............................................................................. 217 Hot Switch Inverter Card (Slot 4) (Not Used)..................................................... 217 Temperature...................................................................................... 217 Oil Level........................................................................................ 217 Temperature and Latch............................................................................ 217 Coolant Level/Flasher............................................................................ 218 Lamp Test........................................................................................ 218 BATTERY EQUALIZER BOX................................................................................ 218 Troubleshooting.................................................................................. 218 BODY-UP SWITCH....................................................................................... 219 Adjustment....................................................................................... 219 Service.......................................................................................... 219 HOIST LIMIT SWITCH................................................................................... 220 Adjustment....................................................................................... 220 Service.......................................................................................... 220 24-VOLT RELAY AND DIODE BOARDS....................................................................... 220 RELAY BOARDS......................................................................................... 221 Description...................................................................................... 221 SERVICE.............................................................................................. 221 To Replace A Relay:.............................................................................. 221 To Replace A Circuit Breaker:.................................................................... 221 To Replace A Circuit Panel Card.................................................................. 222 Relay Board Components........................................................................... 222 Installing Additional Circuits................................................................... 223 DIODE BOARD 1.................................................................................... 224 Diode Testing.................................................................................... 224 CIRCUIT BREAKERS..................................................................................... 226 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX............................................................ 227 BATTERY CHARGING SYSTEM.................................................................................. 231 BATTERY CHARGING SYSTEM.............................................................................. 231 ELECTRICAL SYSTEM DESCRIPTION.................................................................... 231 CHARGE VOLT AND AMP VALUES....................................................................... 231 BATTERY.......................................................................................... 231 Maintenance and Service...................................................................... 231 Troubleshooting.............................................................................. 232 Undercharging................................................................................ 232 Overcharging................................................................................. 232 Corrosion.................................................................................... 232 Acid Levels.................................................................................. 232 Non-Use or Storage........................................................................... 232 Freezing..................................................................................... 233 BATTERY CHARGING ALTERNATOR.......................................................................... 234 GENERAL INFORMATION.............................................................................. 234 General Description.......................................................................... 234 Terminal Identification and Location......................................................... 235 Battery Positive (B+)........................................................................ 235 Battery Negative (B-)........................................................................ 235 DC Output (D+)............................................................................... 235 AC Output (R)................................................................................ 235 Regulator Harness Plug Identification........................................................ 235 Alternator Specifications.................................................................... 235 Performance Curve............................................................................ 235 Battery/Alternator Terminology............................................................... 236 WIRING DIAGRAM................................................................................... 238 DIMENSIONS AND TORQUE VALUES..................................................................... 239 PERIODIC MAINTENANCE............................................................................. 240 TESTING.............................................................................................. 240 GENERAL INFORMATION.............................................................................. 240 Troubleshooting Alternator (On-Truck)........................................................ 240 Equipment Required........................................................................... 240 Preliminary Checks........................................................................... 240 Test Set-up.................................................................................. 242 Test Procedure............................................................................... 243 REGULATOR TESTING................................................................................ 244 Regulator Bypass Test (No Output)............................................................ 244 Regulator Bypass Test (Amp Rating)........................................................... 245 BENCH TESTING.................................................................................... 246 Equipment.................................................................................... 246 Identification Record........................................................................ 246 Advanced Troubleshooting..................................................................... 246 Bench Test 1: No-Load Test................................................................... 246 Bench Test 2: Full Load Test................................................................. 247 Bench Test 3: Regulator Bypass Test.......................................................... 247 STATIC TESTING................................................................................... 248 Equipment.................................................................................... 248 Identification Record........................................................................ 248 Regulator Tester............................................................................. 248 Check For Shorted Power Transistor........................................................... 248 Circuit Tests................................................................................ 249 FIELD COIL TESTS................................................................................. 250 Field Coil Test 1: Check for Open or Shorted Field Coil...................................... 250 Field Coil Test 2: Check For Grounded Field Coil............................................. 250 STATOR TESTS..................................................................................... 251 Stator Test 1: Check For Stator-To-Stator Continuity......................................... 251 Stator Test 2: Check For Grounded Stators.................................................... 252 THERMAL SWITCH TEST.............................................................................. 252 Initial Test................................................................................. 252 Verifying a Faulty Thermal Switch............................................................ 253 TROUBLESHOOTING TIPS............................................................................. 254 ALTERNATOR........................................................................................... 258 ALTERNATOR REPAIR................................................................................ 258 Removal...................................................................................... 258 Installation................................................................................. 260 Special Tools and Lubricants................................................................. 260 Epoxy Adhesive............................................................................... 261 Liquid Threadlockers......................................................................... 261 Elastoplastic Silicone Resin................................................................. 261 ALTERNATOR EXPLODED VIEW......................................................................... 264 ALTERNATOR DISASSEMBLY........................................................................... 266 Regulator Removal............................................................................ 266 Fan Removal.................................................................................. 267 Pulley Removal............................................................................... 268 Anti-Drive End Housing Removal............................................................... 268 Anti-Drive End Rotor Removal................................................................. 270 Drive End Housing Removal.................................................................... 272 Drive End Rotor Removal...................................................................... 278 Field Coil Removal........................................................................... 279 Drive End and/or Anti-Drive End Stator Removal............................................... 281 CLEANING AND INSPECTION.......................................................................... 283 ALTERNATOR ASSEMBLY.............................................................................. 283 Anti-Drive End Stator Installation........................................................... 283 Drive End Stator Installation................................................................ 285 Field Coil Installation...................................................................... 288 Drive End Bearing Installation............................................................... 290 Drive End Rotor Installation................................................................. 292 Rotor and Rotor Shaft Installation........................................................... 292 Drive End Housing Installation............................................................... 293 Anti-Drive End Rotor Installation............................................................ 297 Anti-Drive End Housing Installation.......................................................... 298 Regulator Installation....................................................................... 301 THERMAL SWITCH................................................................................... 302 Removal...................................................................................... 302 Installation................................................................................. 304 SUPPORT STAND.................................................................................... 304 SECTION D35 - PAYLOAD METER III - INDEX...................................................................... 305 OPERATION SECTION........................................................................................ 311 Introduction......................................................................................... 311 Data Summary..................................................................................... 311 Data Gathering................................................................................... 311 COMPONENT DESCRIPTION................................................................................ 312 System Diagram................................................................................... 312 Suspension Pressure Sensors...................................................................... 312 Inclinometer..................................................................................... 312 Operator Display................................................................................. 312 Operator Switch.................................................................................. 313 Speed Input...................................................................................... 313 Body-Up Switch................................................................................... 313 Brake Lock Switch................................................................................ 313 Payload Meter.................................................................................... 313 Communications Ports............................................................................. 313 Key Switch Input................................................................................. 314 Payload Meter Power.............................................................................. 314 Load Lights...................................................................................... 314 Wiring and Termination........................................................................... 315 TCI Outputs...................................................................................... 315 OPERATOR’S DISPLAY AND SWITCH........................................................................ 316 Reading the Speedometer.......................................................................... 316 Reading the Load Display......................................................................... 316 Using the Operator ID............................................................................ 316 Using the Load and Ton Counter................................................................... 316 Total Ton Counter................................................................................ 316 Total Load Counter............................................................................... 317 Clearing the Counters............................................................................ 317 Viewing Live Sensor Data......................................................................... 317 Other Display Messages........................................................................... 317 PAYLOAD OPERATION AND CALCULATION.................................................................... 318 Description of Haul Cycle States................................................................. 318 Haul Cycle Description........................................................................... 318 Load Calculation................................................................................. 319 Carry Back....................................................................................... 319 Measurement Accuracy............................................................................. 319 SOURCES FOR PAYLOAD ERROR............................................................................ 319 Payload Error.................................................................................... 319 Loading Conditions............................................................................... 320 Pressure Sensors................................................................................. 320 Swingloads....................................................................................... 320 Speed and Distance............................................................................... 320 HAUL CYCLE DATA...................................................................................... 320 Haul Cycle Data.................................................................................. 321 Haul Cycle Warning Flags......................................................................... 322 Frame Torque Data................................................................................ 323 Sprung Weight Data............................................................................... 323 Maximum Speed Data............................................................................... 323 Alarm Records.................................................................................... 323 Fault Code Data.................................................................................. 324 PC SOFTWARE OVERVIEW................................................................................. 325 PC Overview...................................................................................... 325 System Configuration............................................................................. 325 Installing the PLMIII Software................................................................... 325 DOWNLOADING DATA..................................................................................... 326 PLM III SYSTEM CONFIGURATION......................................................................... 327 Starting Communications.......................................................................... 327 Displayed Payload Units.......................................................................... 327 Time Units....................................................................................... 327 Connection Menu.................................................................................. 327 Connecting to the Payload Meter.................................................................. 328 Configure the Payload Meter...................................................................... 328 Setting the Date and Time........................................................................ 328 Setting the Truck Type........................................................................... 329 Setting the Gauge Display Units.................................................................. 329 Setting the Frame Serial Number.................................................................. 329 Setting the Truck Number......................................................................... 329 Setting the Komatsu Distributor.................................................................. 329 Setting the Komatsu Customer..................................................................... 329 Clean Truck Tare................................................................................. 330 Inclinometer Calibration......................................................................... 330 DATA ANALYSIS........................................................................................ 331 Creating a Query................................................................................. 331 Sorting on Truck Unit Number..................................................................... 331 Sorting on Truck Type............................................................................ 331 Sorting on Date Range............................................................................ 332 Sorting on Time Range............................................................................ 332 Payload Detail Screen............................................................................ 333 Creating Reports................................................................................. 333 Summary - One Page Report........................................................................ 334 Detailed - Multi-Page Report..................................................................... 334 Creating Graphs.................................................................................. 335 Exporting Data................................................................................... 335 CSV Export....................................................................................... 335 Compressed....................................................................................... 337 Importing Data................................................................................... 337 Deleting Haul Cycle Records...................................................................... 337 Viewing Alarms................................................................................... 338 Deleting Alarm Records........................................................................... 338 TROUBLESHOOTING SECTION.................................................................................. 339 TROUBLESHOOTING...................................................................................... 339 Viewing Active Alarms............................................................................ 339 Real-Time Data Display........................................................................... 339 Testing the Payload Lights....................................................................... 340 Creating Log Files of Inputs..................................................................... 340 Daily Inspections................................................................................ 340 Periodic Maintenance............................................................................. 340 Abnormal Displays at Power-Up.................................................................... 341 No Payload Display When Key Switch is Turned On.................................................. 342 No Display on Speedometer........................................................................ 343 No Display on Operator Display................................................................... 343 No Communications With PC........................................................................ 344 Load Lights Don’t Light During Loading........................................................... 345 Load Lights Remain On............................................................................ 346 Load Lights Remain On During Dumping............................................................. 346 Display Doesn't Clear When The Load Is Dumped.................................................... 346 Calibration Problems............................................................................. 347 Alarm 1 - Left-Front Pressure High............................................................... 348 Alarm 2 - Left-Front Pressure Low................................................................ 348 Troubleshoot Wiring to Left-Front Suspension..................................................... 348 Alarm 3 - Right-Front Pressure High.............................................................. 349 Alarm 4 - Right-Front Pressure Low............................................................... 349 Troubleshoot Wiring to Right-Front Suspension.................................................... 349 Alarm 5 - Left-Rear Pressure High................................................................ 350 Alarm 6 - Left-Rear Pressure Low................................................................. 350 Troubleshoot Wiring to Left-Rear Suspension...................................................... 350 Alarm 7 - Right-Rear Pressure High............................................................... 351 Alarm 8 - Right-Rear Pressure Low................................................................ 351 Troubleshoot Wiring to Right-Rear Suspension..................................................... 351 Alarm 9 - Inclinometer High...................................................................... 352 Alarm 10 - Inclinometer Low...................................................................... 352 Troubleshoot Inclinometer Wiring................................................................. 352 Alarm 13 - Body-Up Input Failure................................................................. 353 Alarm 16 - Memory Write Failure.................................................................. 354 Alarm 17 - Memory Read Failure................................................................... 354 Alarm 18......................................................................................... 355 Alarm 19......................................................................................... 355 Alarm 22......................................................................................... 355 Operator Switch Doesn't Work..................................................................... 356 Alarm 26 - User Switch Fault - SELECT............................................................ 356 Alarm 27 - User Switch Fault - SET............................................................... 356 Connector Map.................................................................................... 357 Connectors....................................................................................... 358 PLMIII CHECKOUT PROCEDURE................................................................................ 359 General Description.................................................................................. 359 Tools Required....................................................................................... 359 Checkout Procedure................................................................................... 359 PLMIII CHECKOUT PROCEDURE CONFIRMATION............................................................... 363 Flashburn Programming............................................................................ 363 Confirmation Checklist........................................................................... 365 SECTION E - ELECTRICAL PROPULSION COMPONENTS - INDEX............................................................. 367 SECTION E2 - ELECTRICAL PROPULSION COMPONENTS - INDEX........................................................ 369 ELECTRICAL PROPULSION COMPONENTS......................................................................... 373 GENERAL SYSTEM DESCRIPTION........................................................................... 373 CONTROL SYSTEM....................................................................................... 373 System Operation................................................................................. 374 FL275 Panel...................................................................................... 375 CARD REPLACEMENT..................................................................................... 376 Removal.......................................................................................... 376 Installation..................................................................................... 376 Card Repair...................................................................................... 376 Panel Wiring..................................................................................... 376 COMPUTER DESCRIPTION................................................................................. 377 Microprocessor................................................................................... 377 Download Capability.............................................................................. 377 SOFTWARE............................................................................................. 377 Base Monitor Program............................................................................. 377 Runtime Monitor Program - OBJ Running Code....................................................... 377 Configuration Software - CFG..................................................................... 378 PTU - Portable Test Unit Code.................................................................... 378 System Regulation................................................................................ 378 Propulsion....................................................................................... 379 Retarding........................................................................................ 379 TWO-DIGIT DISPLAY PANEL.............................................................................. 380 The Coded Number................................................................................. 380 Events........................................................................................... 380 Frames........................................................................................... 381 Windows.......................................................................................... 381 System Categories................................................................................ 381 Limits On Resetting Faults....................................................................... 381 NA Faults........................................................................................ 382 Event Sequence................................................................................... 382 Resetting Events................................................................................. 382 Event Descriptions............................................................................... 382 Subcode Descriptions............................................................................. 382 2-DIGIT DISPLAY PANEL SUBCODES....................................................................... 390 PORTABLE TEST UNIT (PTU)................................................................................. 393 DESCRIPTION.......................................................................................... 393 Operational Hints................................................................................ 393 SOFTWARE INSTALLATION PREPARATION.................................................................... 394 HARD DISK SPACE REQUIREMENTS......................................................................... 394 SOFTWARE INSTALLATION ON PTU......................................................................... 394 PTU/Truck Communication Problems................................................................. 395 THE MAIN MENU........................................................................................ 396 Quit Menu........................................................................................ 396 PTU Talk To Truck................................................................................ 396 View PTU Saved Files............................................................................. 396 List Stat Data Files............................................................................. 396 Truck Setup (CFG)................................................................................ 396 Select Truck Setup............................................................................... 396 Update CFG Version............................................................................... 396 Change PTU Password.............................................................................. 396 CONFIGURATION (CFG) FILE CONVERSION.................................................................. 398 Conversion Procedure............................................................................. 398 Convert Old CFG files for New software........................................................... 399 STATEX CONFIGURATION FILES........................................................................... 402 0) Source Directory: . . ........................................................................ 402 1) Select A Truck Configuration . . ............................................................. 403 2) View Truck Configuration: Data Curves . . .................................................... 404 3) Change/View Serial and Model Numbers . . ..................................................... 405 4) View Options . . ............................................................................. 405 5) Change/View Truck Specifics . . .............................................................. 407 6) Change/View Overspeeds . . ................................................................... 409 7) Save a Truck Configuration, filename: . . .................................................... 410 8) Save Directory: . . .......................................................................... 411 CHANGE PTU PASSWORD.................................................................................. 412 PROGRAMMING THE TRUCK................................................................................ 413 Connect PTU to the Truck......................................................................... 413 Select Configuration File........................................................................ 413 Activate The PTU Mode............................................................................ 413 Check Object Code Version........................................................................ 414 Download Configuration Files..................................................................... 415 Date And Time.................................................................................... 416 Event Data....................................................................................... 417 Statistical Data................................................................................. 419 View Counters.................................................................................... 419 View Profiles.................................................................................... 419 Upload Statistical Data To A File................................................................ 419 Statistical Data Codes - Counters................................................................ 420 STATISTICAL DATA CODES - COUNTERS.................................................................... 421 STATISTICAL DATA CODES - PROFILES.................................................................... 426 TRUCK SPECIFIC INFORMATION........................................................................... 430 Temporary Truck Settings......................................................................... 431 MISCELLANEOUS FEATURES............................................................................... 432 Saving Data...................................................................................... 432 PTU Abbreviations................................................................................ 433 Other Menu Selections............................................................................ 433 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS........................................................... 434 ALTERNATOR........................................................................................... 434 ELECTRIC WHEEL MOTORS................................................................................ 434 RETARDING GRIDS...................................................................................... 434 ELECTRONIC ACCELERATOR AND RETARD PEDALS............................................................. 434 Removal.......................................................................................... 434 Installation..................................................................................... 434 Disassembly...................................................................................... 435 Reassembly....................................................................................... 435 COOLING BLOWER WARNING SYSTEM........................................................................ 435 Operation........................................................................................ 435 Test............................................................................................. 435 Removal.......................................................................................... 436 Installation..................................................................................... 436 ELECTRICAL CONTROL CABINET............................................................................... 437 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS................................................... 442 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III....................................................... 443 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.......................................................... 445 SECTION E3 - STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE - INDEX......................................... 445 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.......................................................... 449 GENERAL INFORMATION.................................................................................. 449 COMMUNICATIONS PORT CHECK............................................................................ 450 PTU Hookup....................................................................................... 450 4.0 SEQUENCE TESTS - (ENGINE NOT ON)................................................................. 451 Preparation and Setup............................................................................ 451 CONTROL SYSTEM SELF-TEST......................................................................... 452 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT......................................................... 452 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT........................................................... 453 PTU Setup.................................................................................... 453 4.3 REVERSER AND PROPULSION CONTACTORS CHECK..................................................... 454 4.4 NOT USED..................................................................................... 455 4.5 RETARD CONTACTORS OPERATION CHECK............................................................ 455 4.6 GROUND FAULT SENSING CHECK................................................................... 455 4.7 GROUND FAULT IN RETARD OPERATION CHECK....................................................... 456 4.8 OVERRIDE OPERATION CHECK..................................................................... 456 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK............................................................ 457 4.10 OVERSPEED RETARD OPERATION CHECK............................................................ 457 4.11 HOIST INTERLOCK OPERATION CHECK............................................................. 458 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.................................................... 458 Return to Main Menu.......................................................................... 458 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL............................................. 459 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU................................................ 459 5.2 DIGITAL INPUT CHECKS......................................................................... 460 5.3 DIGITAL OUTPUT CHECKS........................................................................ 461 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL..................................................... 465 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU..................................................... 465 6.2 ANALOG INPUT CHECKS.......................................................................... 466 6.3 FREQUENCY INPUT CHECKS....................................................................... 470 Return to Main Menu.......................................................................... 471 7.0 SPEED EVENT CHECKS............................................................................... 471 Preparation and Setup............................................................................ 471 Setup PTU........................................................................................ 471 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK...................................... 472 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK........................... 472 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK.......................... 472 7.4 OTHER SPEED EVENTS CHECKS.................................................................... 472 Return to Main Menu.......................................................................... 472 8.0 RETARD SPEED CONTROL SYSTEM CHECK................................................................ 473 Preparation and Setup............................................................................ 473 Setup PTU........................................................................................ 473 8.1 OVERSPEED PICKUP AND DROPOUT CHECK........................................................... 473 8.2 RETARD POT MAXIMUM SETTING CHECK............................................................. 473 8.3 RETARD POT MINIMUM SETTING CHECK............................................................. 473 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL........................................... 474 Return to Main Menu.......................................................................... 474 9.0 LOAD TEST USING TRUCK RETARD GRIDS............................................................... 474 Setup and Preparation............................................................................ 474 PTU Setup........................................................................................ 474 9.1 LOAD TEST.................................................................................... 475 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING.......................................................... 475 Setup PTU........................................................................................ 475 10.1 RETARD CHECK................................................................................ 476 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT..................................................... 477 11.1 BRAKE SYSTEM INTERLOCKS CHECK............................................................... 477 Preparation.................................................................................. 477 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT...................................................... 477 11.3 SYNC TRANSFORMER CHECKOUT................................................................... 478 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT.................................................. 478 11.5 BATTERY BOOST ADJUSTMENT.................................................................... 478 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST................................................. 478 11.7 MOTOR ROTATION TEST......................................................................... 479 11.8 GROUND FAULT CHECKS......................................................................... 479 12.0 MISCELLANEOUS CHARTS............................................................................ 480 12.1 WHEEL MOTOR GEAR RATIOS..................................................................... 480 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS.............................................................. 481 12.3 ENGINE OPTIONS.............................................................................. 482 SECTION G - DRIVE AXLE, SPINDLE AND WHEELS - INDEX............................................................... 483 SECTION G2 - TIRES AND RIMS - INDEX.......................................................................... 485 TIRES AND RIMS........................................................................................... 487 GENERAL INFORMATION.................................................................................. 487 TIRES................................................................................................ 487 Handling Tires................................................................................... 487 Tire Maintenance................................................................................. 488 Storing Tires After Removal...................................................................... 488 FRONT TIRES AND RIMS................................................................................. 489 Removal.......................................................................................... 489 Installation..................................................................................... 490 REAR TIRES AND RIMS.................................................................................. 491 Removal.......................................................................................... 491 Installation..................................................................................... 492 RIM.............................................................................................. 493 Tire Removal..................................................................................... 493 RIM AND TIRE PREPARATION............................................................................. 494 LUBRICANTS........................................................................................... 494 TIRE INSTALLATION.................................................................................... 495 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX............................................................. 497 FRONT WHEEL HUB AND SPINDLE.............................................................................. 499 WHEEL HUB AND SPINDLE ASSEMBLY....................................................................... 499 Removal.......................................................................................... 499 Installation..................................................................................... 501 Disassembly...................................................................................... 502 Cleaning and Inspection.......................................................................... 503 Assembly......................................................................................... 503 Wheel Bearing Adjustment (Spindle Vertical)...................................................... 506 Wheel Bearing Adjustment (Tire Mounted).......................................................... 507 STEERING CYLINDERS AND TIE ROD....................................................................... 508 Spherical Bearing Wear Limits.................................................................... 508 Removal.......................................................................................... 509 Installation..................................................................................... 511 Bearing Replacement.............................................................................. 511 TOE-IN ADJUSTMENT.................................................................................... 512 SECTION G4 - REAR AXLE HOUSING - INDEX....................................................................... 513 REAR AXLE HOUSING........................................................................................ 515 PIVOT PIN............................................................................................ 515 Removal.......................................................................................... 515 Installation..................................................................................... 516 PIVOT EYE BEARING.................................................................................... 516 Disassembly...................................................................................... 516 Assembly......................................................................................... 517 PIVOT EYE REPAIR..................................................................................... 517 Removal.......................................................................................... 517 Disassembly...................................................................................... 517 Bushing (New).................................................................................... 517 Pivot Eye Bore (New)............................................................................. 517 Assembly......................................................................................... 517 Installation..................................................................................... 518 ANTI-SWAY BAR........................................................................................ 518 Removal.......................................................................................... 518 Installation..................................................................................... 518 Disassembly...................................................................................... 519 Cleaning and Inspection.......................................................................... 519 Assembly......................................................................................... 519 SECTION G5 - REAR AXLE HOUSING - INDEX....................................................................... 521 REAR AXLE HOUSING........................................................................................ 523 REAR AXLE HOUSING.................................................................................... 523 Removal.......................................................................................... 523 Installation..................................................................................... 523 WHEEL MOTOR.......................................................................................... 523 Removal.......................................................................................... 523 Cleaning and Inspection.......................................................................... 524 Installation..................................................................................... 524 Maximum Cap Screw Usage.......................................................................... 524 REAR AXLE HOUSING BUMPER PAD......................................................................... 525 SECTION H - SUSPENSIONS - INDEX.................................................................................. 527 SECTION H2 - FRONT SUSPENSIONS - INDEX....................................................................... 529 FRONT SUSPENSION......................................................................................... 531 Removal.............................................................................................. 531 Installation......................................................................................... 533 Turn-of-the-Nut Tightening Procedure................................................................. 534 Disassembly.......................................................................................... 535 Cleaning and Inspection.............................................................................. 536 Assembly (Bearing Only).............................................................................. 536 Suspension Assembly (Complete)....................................................................... 536 SUSPENSION PRESSURE TEST............................................................................. 538 SECTION H3 - REAR SUSPENSION - INDEX......................................................................... 541 REAR SUSPENSIONS......................................................................................... 543 Removal.............................................................................................. 544 Installation......................................................................................... 546 Disassembly.......................................................................................... 546 Cleaning and Inspection.............................................................................. 546 Assembly............................................................................................. 547 SUSPENSION PRESSURE TEST............................................................................. 549 SECTION H4 - OILING AND CHARGING PROCEDURE - INDEX........................................................... 551 OILING AND CHARGING PROCEDURE............................................................................ 553 GENERAL.............................................................................................. 553 EQUIPMENT LIST....................................................................................... 553 Hydrair® Charging Kit............................................................................ 553 Installation of Charging Kit..................................................................... 553 Removal of Charging Kit.......................................................................... 554 Support Blocks For Oiling and Charging Dimensions................................................ 554 FRONT SUSPENSION..................................................................................... 555 Front Suspension Oiling.......................................................................... 555 Front Suspension Nitrogen Charging............................................................... 556 REAR SUSPENSION...................................................................................... 558 Rear Suspension Oiling........................................................................... 558 Rear Suspension Nitrogen Charging................................................................ 560 OIL AND NITROGEN SPECIFICATIONS CHART.................................................................... 561 SECTION J - BRAKE CIRCUIT - INDEX................................................................................ 563 SECTION J2 - BRAKE CIRCUIT - INDEX........................................................................... 565 BRAKE CIRCUIT............................................................................................ 567 GENERAL DESCRIPTION.................................................................................. 567 SERVICE BRAKE CIRCUIT................................................................................ 567 SECONDARY BRAKING AND AUTOMATIC APPLY................................................................ 569 PARKING BRAKE CIRCUIT................................................................................ 569 Normal Operation (key switch on, engine on)...................................................... 569 BRAKE LOCK CIRCUIT................................................................................... 570 WARNING CIRCUIT...................................................................................... 570 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX......................................................... 573 BRAKE CIRCUIT COMPONENT SERVICE.......................................................................... 575 BRAKE VALVE.......................................................................................... 575 Rebuild Criteria................................................................................. 575 Removal.......................................................................................... 575 Installation..................................................................................... 577 Disassembly...................................................................................... 579 Cleaning and Inspection.......................................................................... 581 ASSEMBLY............................................................................................. 581 Actuator Base Threaded Inserts................................................................... 581 Boot and Cap..................................................................................... 581 Valve Body Seal Installation..................................................................... 582 Regulator Sleeve O-Ring Installation............................................................. 583 Actuator Plunger O-Ring Installation............................................................. 583 Assembly of Valve................................................................................ 583 DIFFERENTIAL PRESSURE SWITCH......................................................................... 584 Disassembly...................................................................................... 585 Cleaning and Inspection.......................................................................... 585 Assembly......................................................................................... 585 VALVE BENCH TEST AND ADJUSTMENT...................................................................... 585 Test Set Up Procedure............................................................................ 587 Brake Valve Output Pressure Adjustment........................................................... 587 Differential Pressure Switch Test................................................................ 588 Final Test and Adjustment........................................................................ 588 Installation Of Brake Pedal Actuator Assembly to Brake Valve..................................... 589 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (DUAL FUNCTION PEDAL)................. 591 Installation of Retard Pedal To Brake Pedal...................................................... 591 HYDRAULIC BRAKE ACCUMULATORS......................................................................... 592 Brake Accumulator Bleed-Down Procedure........................................................... 592 Removal.......................................................................................... 592 Installation..................................................................................... 594 Disassembly...................................................................................... 594 Cleaning and Inspection.......................................................................... 596 Assembly......................................................................................... 596 Leak Testing..................................................................................... 598 BRAKE ACCUMULATOR CHARGING........................................................................... 599 Temperature During Precharge..................................................................... 601 ACCUMULATOR STORAGE.................................................................................. 602 Installation..................................................................................... 602 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX....................................................... 605 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................................ 607 EQUIPMENT REQUIRED................................................................................... 610 INITIAL SYSTEM SET-UP................................................................................ 611 Parking Brake.................................................................................... 611 Service Brakes................................................................................... 612 Brake Lock/Secondary............................................................................. 612 Low Brake Pressure and Auto Apply................................................................ 613 Reapplications................................................................................... 613 Differential Pressure Switch..................................................................... 613 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................................ 615 CHECK-OUT PROCEDURE...................................................................................... 618 HYDRAULIC BRAKE SYSTEM DATA SHEET........................................................................ 618 SECTION J5 - FRONT DISC BRAKES - INDEX....................................................................... 621 FRONT DISC BRAKES........................................................................................ 623 BRAKE CALIPER........................................................................................ 623 Removal.......................................................................................... 623 Installation..................................................................................... 624 Disassembly...................................................................................... 625 Cleaning and Inspection.......................................................................... 625 Assembly......................................................................................... 627 BRAKE LINING......................................................................................... 627 Replacement...................................................................................... 627 FRONT SERVICE BRAKE BURNISHING....................................................................... 629 BRAKE BLEEDING PROCEDURE......................................................................... 630 REAR DISC BRAKES......................................................................................... 633 REAR BRAKES.......................................................................................... 633 CALIPER, DISC, AND PARKING BRAKE..................................................................... 633 Removal.......................................................................................... 633 Installation..................................................................................... 634 Trucks equipped with one-piece adapter........................................................... 637 Removal.......................................................................................... 637 Installation..................................................................................... 638 CALIPER PISTON....................................................................................... 639 Piston Assembly Removal.......................................................................... 639 Inspection....................................................................................... 639 Piston Assembly Installation..................................................................... 640 FUNCTIONAL TEST OF PISTON ASSEMBLY................................................................... 641 Return Spring Force.............................................................................. 641 Built-In Clearance............................................................................... 641 Grip Force....................................................................................... 642 Grip Force Measurement........................................................................... 644 Spring Force Measurement......................................................................... 645 Disassembly of Piston Assembly................................................................... 646 Assembly of Piston Assembly...................................................................... 647 BENCH TEST........................................................................................... 647 BRAKE LINING......................................................................................... 648 Replacement...................................................................................... 648 SERVICE BRAKE BURNISHING............................................................................. 651 SAFETY PRECAUTIONS............................................................................... 651 Rear Brake Conditioning...................................................................... 652 BRAKE BLEEDING PROCEDURE......................................................................... 653 Spring Force Measurement..................................................................... 654 SECTION J6 - REAR BRAKES - INDEX............................................................................. 631 SECTION J7 - PARKING BRAKE - INDEX........................................................................... 655 PARKING BRAKE............................................................................................ 657 GENERAL INFORMATION.................................................................................. 657 PARKING BRAKE CALIPER................................................................................ 657 Lining Thickness Inspection...................................................................... 657 Removal.......................................................................................... 658 Installation..................................................................................... 658 Parking Brake Adjustment......................................................................... 659 Parking Brake Caliper Disassembly................................................................ 660 Cleaning and Inspection.......................................................................... 661 Parking Brake Caliper Assembly................................................................... 662 PARKING BRAKE LINING REPLACEMENT..................................................................... 662 PARKING BRAKE BURNISH PROCEDURE...................................................................... 662 Lining Conditioning.............................................................................. 662 BRAKE BLEEDING PROCEDURE............................................................................. 663 SECTION L - HYDRAULIC SYSTEM - INDEX............................................................................. 665 SECTION L2 - HYDRAULIC SYSTEM OVERVIEW - INDEX............................................................... 667 HYDRAULIC SYSTEM OVERVIEW................................................................................ 669 Hoist Circuit Operation.............................................................................. 669 Steering, Brake and Pantograph Circuit Operation..................................................... 669 Axle Blower System Operation......................................................................... 673 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX....................................................... 675 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................................ 677 HOIST PUMP........................................................................................... 677 Removal.......................................................................................... 677 Installation..................................................................................... 679 Disassembly...................................................................................... 679 Inspection....................................................................................... 682 Assembly......................................................................................... 683 PISTON PUMP...................................................................................... 688 Removal...................................................................................... 688 Installation................................................................................. 689 Disassembly.................................................................................. 691 Inspection of Parts.......................................................................... 697 Assembly..................................................................................... 699 AXLE BLOWER HYDRAULIC MOTOR.............................................................................. 704 Removal.............................................................................................. 704 Installation......................................................................................... 704 Rear Axle Blower Housing............................................................................. 704 Disassembly...................................................................................... 704 Assembly......................................................................................... 705 Disassembly...................................................................................... 707 Inspection....................................................................................... 709 Assembly......................................................................................... 710 Trouble Shooting................................................................................. 711 Hand Wheel Control................................................................................... 712 Disassembly...................................................................................... 712 Assembly......................................................................................... 712 HYDRAULIC TANK....................................................................................... 714 Filling Instructions............................................................................. 714 Removal.......................................................................................... 715 Installation..................................................................................... 715 HYDRAULIC TANK STRAINER AND DIFFUSER................................................................. 715 Removal.......................................................................................... 715 Inspect and Clean................................................................................ 716 Installation..................................................................................... 716 SECTION L4 - STEERING CIRCUIT - INDEX........................................................................ 717 STEERING CIRCUIT......................................................................................... 719 STEERING CIRCUIT OPERATION........................................................................... 719 COMPONENT DESCRIPTION................................................................................ 720 Steering Control Valve........................................................................... 720 Unloader Valve................................................................................... 721 Bleed-Down Manifold Valve........................................................................ 721 Flow Amplifier................................................................................... 727 FLOW AMPLIFIER SYSTEM OPERATION...................................................................... 728 No Steer......................................................................................... 728 Steering Left.................................................................................... 730 Steering Right................................................................................... 732 No Steer, External Shock Load.................................................................... 734 Steering Pump.................................................................................... 736 High Pressure Filter............................................................................. 736 Accumulators..................................................................................... 736 Low Precharge Warning Switch..................................................................... 736 SECTION L5 - STEERING CONTROL VALVE - INDEX.................................................................. 737 STEERING CONTROL VALVE................................................................................... 739 Removal.............................................................................................. 739 Installation......................................................................................... 740 STEERING CONTROL VALVE REBUILD....................................................................... 741 Disassembly...................................................................................... 741 Cleaning and Inspection.......................................................................... 742 Assembly......................................................................................... 742 BRAKE / STEERING PUMP................................................................................ 746 Removal.......................................................................................... 746 Installation..................................................................................... 748 Disassembly...................................................................................... 749 Inspection of Parts.............................................................................. 749 Assembly......................................................................................... 751 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX....................................................... 753 STEERING CIRCUIT COMPONENT REPAIR........................................................................ 755 BLEED DOWN MANIFOLD.................................................................................. 755 Removal.......................................................................................... 755 Installation..................................................................................... 755 ACCUMULATOR.......................................................................................... 756 Removal.......................................................................................... 756 Installation..................................................................................... 757 Disassembly...................................................................................... 758 Cleaning and Inspection.......................................................................... 758 Assembly......................................................................................... 758 LEAK TESTING......................................................................................... 760 STEERING ACCUMULATOR CHARGING PROCEDURE.............................................................. 761 Temperature During Precharge..................................................................... 764 ACCUMULATOR STORAGE PROCEDURES....................................................................... 765 Instructions For Storing Bladder Accumulators.................................................... 765 Instructions For Installing A Bladder Accumulator That Was In A Parts Warehouse Or In Storage.... 765 Bladder Storage Procedures....................................................................... 766 FLOW AMPLIFIER....................................................................................... 766 Removal.......................................................................................... 766 Installation..................................................................................... 766 Disassembly...................................................................................... 766 Assembly......................................................................................... 769 STEERING CYLINDERS................................................................................... 771 Disassembly...................................................................................... 771 Piston Seal & Bearing Installation............................................................... 771 Cylinder Assembly................................................................................ 771 Test............................................................................................. 771 TROUBLESHOOTING CHART................................................................................ 774 SECTION L7 - HOIST CIRCUIT - INDEX........................................................................... 779 HOIST CIRCUIT............................................................................................ 781 COMPONENT DESCRIPTION................................................................................ 782 HYDRAULIC TANK................................................................................... 782 HYDRAULIC PUMP................................................................................... 782 HIGH PRESSURE FILTER............................................................................. 782 HOIST VALVE...................................................................................... 782 HOIST PILOT VALVE................................................................................ 784 BLEEDDOWN MANIFOLD............................................................................... 784 COUNTERBALANCE VALVE MANIFOLD.................................................................... 784 HOIST-UP LIMIT SOLENOID.......................................................................... 784 PILOT OPERATED CHECK VALVE....................................................................... 785 HOIST VALVE OPERATION............................................................................ 785 FLOAT OPERATION.............................................................................. 785 POWER UP OPERATION (Figure 7-5).............................................................. 788 HOLD OPERATION (Figure 7-6).................................................................. 790 POWER DOWN OPERATION (Figure 7-7)............................................................ 792 FLOAT OPERATION (Figure 7-8)................................................................. 793 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX.......................................................... 797 HOIST CIRCUIT COMPONENT REPAIR........................................................................... 799 HOIST VALVE.......................................................................................... 799 Removal.......................................................................................... 799 Installation..................................................................................... 799 O-Ring Replacement............................................................................... 801 INLET SECTION........................................................................................ 802 Disassembly...................................................................................... 802 Cleaning and Inspection.......................................................................... 803 Assembly......................................................................................... 803 REAR SPOOL SECTION (WORK PORTS)...................................................................... 804 Disassembly...................................................................................... 804 Cleaning and Inspection.......................................................................... 806 Assembly......................................................................................... 806 HOIST PILOT VALVE.................................................................................... 808 Removal.......................................................................................... 808 Installation..................................................................................... 808 Disassembly...................................................................................... 809 Cleaning and Inspection.......................................................................... 810 Assembly......................................................................................... 810 HOIST UP LIMIT SOLENOID VALVE........................................................................ 811 HOIST CYLINDERS...................................................................................... 811 Removal.......................................................................................... 811 Installation..................................................................................... 812 Disassembly...................................................................................... 815 Cleaning and Inspection.......................................................................... 816 SS1143 Tightening Tool - Assembly Drawing........................................................ 817 ASSEMBLY OF QUILL AND CYLINDER....................................................................... 817 Quill Installation............................................................................... 817 Installation Of Check Balls And Plugs In Quill................................................... 818 Assembly of Cylinder............................................................................. 820 COUNTERBALANCE MANIFOLD.............................................................................. 821 SECTION L9 - HIGH PRESSURE FILTERS - INDEX................................................................... 823 HYDRAULIC SYSTEM FILTERS................................................................................. 825 HOIST CIRCUIT FILTER................................................................................. 825 Filter Element Replacement....................................................................... 825 Removal.......................................................................................... 826 Installation..................................................................................... 826 Indicator Switch................................................................................. 826 STEERING CIRCUIT FILTER.............................................................................. 827 Filter Element Replacement....................................................................... 827 Removal.......................................................................................... 828 Installation..................................................................................... 828 Indicator Switch................................................................................. 828 INDICATOR SWITCH..................................................................................... 828 Test Procedure................................................................................... 828 SECTION L10 - HYDRAULIC CHECKOUT PROCEDURE - INDEX........................................................... 831 HYDRAULIC CHECKOUT PROCEDURE............................................................................. 833 Initial Start Up and Flushing (Steps 5 - 22)......................................................... 834 Component Checkout and Adjustment (Steps 23 - 34).................................................... 836 Adjustment Procedure for Hoist Counterbalance Cartridge Valve (Steps 34a-34l)........................ 838 Counterbalance Valve Adjustment (Steps f & g):................................................... 840 Manifold reassembly (steps i through k):......................................................... 840 Piston Pump and Axle Box Hydraulic Motor Adjustment (Steps 35 - 50).................................. 840 Oil Cleanliness Check................................................................................ 841 Oil Sampling Location on Truck:.................................................................. 841 Oil Sampling Process and Cleanliness Criteria:................................................... 841 DISABLED TRUCK DUMPING PROCEDURE..................................................................... 842 HOOKUP........................................................................................... 842 DUMPING PROCEDURE................................................................................ 842 Raising the Body:................................................................................ 842 Lowering the Body:............................................................................... 843 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX.................................................................... 851 SECTION M4 - ELECTRIC DRIVE COOLING AIR FILTER SYSTEM - INDEX................................................ 853 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM................................................................. 855 SYSTEM ADJUSTMENT.................................................................................... 855 PUMP................................................................................................. 858 Removal.............................................................................................. 858 Disassembly.......................................................................................... 858 Inspection........................................................................................... 858 Assembly............................................................................................. 858 Installation......................................................................................... 858 BLOWER DRIVE MOTOR................................................................................... 861 Removal.............................................................................................. 861 Disassembly.......................................................................................... 861 Inspection Of Parts.................................................................................. 862 Assembly............................................................................................. 863 Installation......................................................................................... 864 BLOWER BEARING REPAIR................................................................................ 864 Removal.......................................................................................... 864 Replacement...................................................................................... 864 Assembly......................................................................................... 865 AIR CLEANER.......................................................................................... 865 Assembly......................................................................................... 865 Removal.......................................................................................... 865 Assembly......................................................................................... 865 SECTION M7 - ENGINE OIL HEATER - INDEX....................................................................... 867 ENGINE OIL HEATERS....................................................................................... 869 GENERAL INFORMATION.................................................................................. 869 TROUBLESHOOTING...................................................................................... 869 HEATER ELEMENT....................................................................................... 869 Removal.......................................................................................... 869 Installation..................................................................................... 870 SECTION M8 -SPECIAL TOOLS.................................................................................... 871 SECTION N - OPERATORS CAB - INDEX................................................................................ 881 SECTION N2 - TRUCK CAB - INDEX............................................................................... 883 TRUCK CAB................................................................................................ 885 TRUCK CAB............................................................................................ 885 Description...................................................................................... 885 Removal.......................................................................................... 886 Installation..................................................................................... 888 CAB DOOR............................................................................................. 888 Removal.......................................................................................... 888 Installation..................................................................................... 889 Door Adjustment.................................................................................. 889 Door Jam Bolt Adjustment......................................................................... 889 Door Handle Plunger Adjustment................................................................... 891 Replace Door Glass............................................................................... 892 Replace Door Window Regulator.................................................................... 896 Replace Door Handle or Latch Assembly............................................................ 896 Door and Door Hinge Seal Replacement............................................................. 897 Door Opening Seal Removal........................................................................ 897 Installation..................................................................................... 897 GLASS REPLACEMENT.................................................................................... 898 Adhesive-Bonded Windows.......................................................................... 898 Recommended Tools/Supplies....................................................................... 898 Replacement Procedure............................................................................ 898 Windshield and Rear Glass........................................................................ 899 Removal.......................................................................................... 899 Installation..................................................................................... 900 SECTION N3 - CAB COMPONENTS - INDEX.......................................................................... 901 CAB COMPONENTS........................................................................................... 903 WINDSHIELD WIPERS.................................................................................... 903 WIPER MOTOR REPLACEMENT.......................................................................... 903 Removal...................................................................................... 903 Installation................................................................................. 903 WIPER ARM REPLACEMENT............................................................................ 903 Removal...................................................................................... 903 Installation................................................................................. 904 WIPER LINKAGE REPLACEMENT........................................................................ 904 Removal...................................................................................... 904 Installation................................................................................. 905 WINDSHIELD WASHER................................................................................ 905 Operation.................................................................................... 905 Service...................................................................................... 905 SECTION N4 - OPERATOR COMFORT - INDEX........................................................................ 907 HEATER/AIR CONDITIONER................................................................................... 909 CONTROLS............................................................................................. 909 Operation........................................................................................ 909 Heater/Air Conditioner Vents..................................................................... 909 Defroster Vent Control Switch.................................................................... 909 Heat Control Switch.............................................................................. 909 Temperature Control Knob......................................................................... 909 Fan Control Knob................................................................................. 909 Heater/Air Conditioner Selector Switch........................................................... 909 COMPONENTS........................................................................................... 910 Circuit Breakers................................................................................. 910 Relays........................................................................................... 910 Heater Core...................................................................................... 910 Fan Motor and Speed Control...................................................................... 911 Test............................................................................................. 911 Actuators........................................................................................ 911 Test............................................................................................. 911 Cab Air Filter................................................................................... 912 AIR CONDITIONING SYSTEM.................................................................................. 914 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................................ 915 PRINCIPLES OF REFRIGERATION.......................................................................... 915 Air Conditioning................................................................................. 915 Refrigeration - The Act of Cooling............................................................... 916 The Refrigeration Cycle.......................................................................... 916 AIR CONDITIONER SYSTEM COMPONENTS.................................................................... 917 Compressor (Refrigerant Pump).................................................................... 917 Service Valves................................................................................... 917 Receiver-Drier................................................................................... 917 Condenser........................................................................................ 917 Expansion Block Valve............................................................................ 918 Accumulator...................................................................................... 918 Evaporator....................................................................................... 919 ELECTRICAL CIRCUIT................................................................................... 919 Thermostat....................................................................................... 919 Compressor Clutch................................................................................ 920 Trinary™ Switch.................................................................................. 920 SYSTEM SERVICING..................................................................................... 922 SERVICE TOOLS AND EQUIPMENT.......................................................................... 923 Recovery/Recycle Station......................................................................... 923 Leak Detector.................................................................................... 924 Service Valves................................................................................... 924 Vacuum Pump...................................................................................... 924 Manifold Gauge Set............................................................................... 925 Low Side Gauge................................................................................... 925 High Side Gauge.................................................................................. 925 Installing Manifold Gauge Set.................................................................... 926 Purging Air From Service Hoses................................................................... 926 SYSTEM PERFORMANCE TEST.............................................................................. 927 SYSTEM OIL........................................................................................... 928 Handling and Reusing RPAG Oil.................................................................... 928 Oil Quantity..................................................................................... 928 Checking System Oil.............................................................................. 928 REFRIGERANT.......................................................................................... 929 Recycled Refrigerant............................................................................. 929 Reclaimed Refrigerant............................................................................ 929 Refrigerant Quantity............................................................................. 930 R-134a Refrigerant Containers.................................................................... 930 SYSTEM LEAK TESTING.................................................................................. 930 Electronic Leak Detector......................................................................... 931 Tracer Dyes...................................................................................... 931 Soap and Water................................................................................... 931 RECOVERING AND RECYCLING THE REFRIGERANT............................................................. 932 Performing the Recovery Cycle.................................................................... 932 Performing the Recycling Procedure............................................................... 932 Evacuating and Charging the A/C System........................................................... 932 SYSTEM REPAIR........................................................................................ 933 System Flushing.................................................................................. 933 COMPONENT REPLACEMENT................................................................................ 934 Hoses and Fittings............................................................................... 934 Lines............................................................................................ 934 Expansion Valve.................................................................................. 934 Receiver-Drier................................................................................... 934 Thermostat....................................................................................... 934 Compressor....................................................................................... 935 Accumulator...................................................................................... 935 Clutch........................................................................................... 935 Servicing the Compressor Clutch.................................................................. 936 Pulley Removal................................................................................... 938 Clutch Coil Check................................................................................ 939 Pulley Installation.............................................................................. 939 Clutch Assembly Installation..................................................................... 940 EVACUATING THE SYSTEM................................................................................ 941 CHARGING THE A/C SYSTEM.............................................................................. 943 AIR CONDITIONER DRIVE BELT........................................................................... 944 Pulley Alignment................................................................................. 944 Belt Tension..................................................................................... 945 TROUBLESHOOTING...................................................................................... 946 Preliminary Checks............................................................................... 946 Diagnosis of Gauge Readings and System Performance............................................... 946 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS....................................................... 947 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................................... 953 SECTION N5 - OPERATOR CONTROLS - INDEX....................................................................... 955 OPERATOR CONTROLS........................................................................................ 957 STEERING WHEEL AND CONTROLS.......................................................................... 958 STEERING WHEEL................................................................................... 958 HORN BUTTON...................................................................................... 958 TILT/TELESCOPE LEVER............................................................................. 958 MULTI-FUNCTION TURN SIGNAL SWITCH................................................................ 958 Turn Signal Operation........................................................................ 959 High Beam Headlight Operation................................................................ 959 Windshield Wiper Operation................................................................... 959 STEERING COLUMN.................................................................................. 959 Removal...................................................................................... 959 Inspection................................................................................... 960 Installation................................................................................. 960 PEDALS............................................................................................... 960 SERVICE BRAKE PEDAL.............................................................................. 960 DYNAMIC RETARDER PEDAL........................................................................... 961 Optional - Dual Function/Single Pedal........................................................ 961 THROTTLE PEDAL................................................................................... 961 OVERHEAD PANEL CONTROLS AND COMPONENTS............................................................... 962 GRADE/SPEED WARNING CHART........................................................................ 962 RADIO SPEAKERS................................................................................... 962 WINDSHIELD WIPERS................................................................................ 962 WARNING ALARM BUZZER............................................................................. 962 CAB RADIO........................................................................................ 962 WARNING LIGHTS DIMMER CONTROL.................................................................... 962 WARNING/STATUS INDICATOR LIGHT PANEL............................................................. 962 AIR CLEANER VACUUM GAUGES........................................................................ 962 CENTER CONSOLE....................................................................................... 963 TRUCK CONTROLS................................................................................... 964 F-N-R Selector Switch........................................................................ 964 Hoist Control Lever.......................................................................... 964 Trolley Master Control Lever................................................................. 964 CONSOLE SWITCHES AND CONTROLS.................................................................... 964 Cigarette Lighter............................................................................ 964 Window Control Switches...................................................................... 964 Engine Shutdown Switch....................................................................... 964 Override Switch.............................................................................. 965 Retard Speed Control (RSC) Switch............................................................ 965 Retard Speed Control (RSC) Dial.............................................................. 965 Statex III Download Port..................................................................... 966 Engine Diagnostic Port (CENSE)............................................................... 966 Engine Diagnostic Connectors................................................................. 966 Data Storage Button.......................................................................... 966 Passenger Seat............................................................................... 966 PAYLOAD METER.................................................................................... 967 Payload Meter Download Connector............................................................. 967 CAB CLIMATE CONTROL.................................................................................. 968 HEATER/AIR CONDITIONER VENTS..................................................................... 968 HEATER/AIR CONDITIONER CONTROLS AND VENTS........................................................ 968 Defroster Vent Control Switch................................................................ 968 Heat Control Switch.......................................................................... 968 Temperature Control Knob..................................................................... 968 Fan Control Knob............................................................................. 968 Heater/Air Conditioner Vents................................................................. 968 OPERATOR SEAT........................................................................................ 969 ADJUSTMENT....................................................................................... 969 INSTRUMENT PANEL..................................................................................... 970 GENERAL INFORMATION.............................................................................. 970 CONTROL SYMBOLS.................................................................................. 970 CONTROL SWITCHES AND GAUGES...................................................................... 971 Key Switch................................................................................... 972 Engine Shutdown Switch With Timer Delay...................................................... 972 Fog Light Switch............................................................................. 972 Ladder Light Switch.......................................................................... 972 Backup Light Switch.......................................................................... 972 Panel Illumination Lights.................................................................... 972 Cab Air Conditioner/Heater Vents............................................................. 972 Engine Cold Weather Starting Aid Switch...................................................... 972 Rotating Beacon Light Switch................................................................. 973 Heated Mirror Switch......................................................................... 973 Wheel Brake Lock Switch...................................................................... 973 Parking Brake Switch......................................................................... 973 Digital Tachometer........................................................................... 973 Right Turn Signal Indicator Light............................................................ 974 High Beam Headlight Indicator Light.......................................................... 974 Left Turn Signal Indicator Light............................................................. 974 Digital Speedometer/Payload Meter Display.................................................... 974 Voltmeter Gauge.............................................................................. 974 Engine Oil Pressure Gauge.................................................................... 974 Engine Water Temperature Gauge............................................................... 974 Fuel Gauge................................................................................... 974 Engine Hourmeter............................................................................. 975 Headlight Switch............................................................................. 975 Panel Illumination Lights Dimmer Rheostat.................................................... 975 Payload Meter Switch......................................................................... 975 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL...................................................... 976 INDICATOR LIGHT FUNCTIONS........................................................................ 977 High Hydraulic Oil Temperature............................................................... 977 Low Steering Pressure........................................................................ 977 Low Accumulator Precharge Pressure Warning................................................... 977 Electric System Fault Warning................................................................ 978 Low Brake Pressure Indicator................................................................. 978 Low Hydraulic Tank Level..................................................................... 978 Low Automatic Lubrication System Pressure.................................................... 978 Circuit Breaker Tripped...................................................................... 978 Hydraulic Oil Filter......................................................................... 978 Low Fuel Indicator........................................................................... 979 Parking Brake Indicator...................................................................... 979 Service Brake Indicator...................................................................... 979 Body Up Indicator............................................................................ 979 Dynamic Retarding Indicator.................................................................. 979 Stop Engine Warning.......................................................................... 979 Backup Indicator............................................................................. 979 Engine Shutdown Timer Switch- Five Minute Idle............................................... 979 Retard Speed Control......................................................................... 979 Service Engine Indicator (AEM)............................................................... 980 High Wheel Motor Temperature Indicator....................................................... 980 Blower Fault Warning......................................................................... 980 Service Engine Indicator (CENSE)............................................................. 980 Komatsu Engines w/Centry™ Fuel Control....................................................... 980 Hazard Warning Light Switch.................................................................. 980 Lamp Test Switch/Centry™ Diagnostic Test Switch.............................................. 980 CENTRY™ FUEL SYSTEM DIAGNOSTICS...................................................................... 984 GENERAL OPERATION................................................................................ 984 DETERMINING FAULT CODES.......................................................................... 984 EXITING THE DIAGNOSTICS MODE..................................................................... 985 SECTION P - LUBRICATION AND SERVICE - INDEX...................................................................... 987 SECTION P2 - LUBRICATION AND SERVICE - INDEX................................................................. 989 LUBRICATION AND SERVICE.................................................................................. 991 GENERAL INFORMATION.................................................................................. 991 HYDRAULIC TANK SERVICE............................................................................... 991 Adding Oil....................................................................................... 991 COOLING SYSTEM....................................................................................... 992 Coolant Level Check.............................................................................. 992 Radiator Filling Procedure....................................................................... 992 Antifreeze Temperature Recommendations........................................................... 992 10 HOUR LUBE AND MAINTENANCE CHECKS...................................................................... 994 50 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................................... 995 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................. 995 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................. 996 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................. 998 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................................. 999 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................1000 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................1000 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................1001 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................................1001 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX............................................................1003 AUTOMATIC LUBRICATION SYSTEM.............................................................................1005 GENERAL DESCRIPTION..................................................................................1005 SYSTEM COMPONENTS....................................................................................1006 Filter Assembly..................................................................................1006 Hydraulic Motor and Grease Pump..................................................................1006 Reservoir........................................................................................1007 Fixed Pressure Reducing Valve....................................................................1007 Flow Control Valve...............................................................................1007 Solenoid Valve...................................................................................1007 Vent Valve.......................................................................................1007 24VDC Lubrication Cycle Timer....................................................................1007 Time Delay Module................................................................................1007 Pump Cutoff Pressure Switch......................................................................1007 Unloader Valve...................................................................................1007 Pressure Switch..................................................................................1007 Pressure Gauge...................................................................................1009 Manual Override Button...........................................................................1009 Injectors........................................................................................1009 SYSTEM OPERATION.....................................................................................1011 Normal Operation.................................................................................1011 Pressure Failure Detection Circuits..............................................................1012 GENERAL INSTRUCTIONS.....................................................................................1013 LUBRICANT REQUIRED FOR SYSTEM........................................................................1013 SYSTEM PRIMING.......................................................................................1013 LUBRICANT PUMP.......................................................................................1014 Pump Housing Oil Level...........................................................................1014 Pump Pressure Control............................................................................1014 FILTER AND RESERVOIR.................................................................................1014 Filter Assembly Element..........................................................................1015 INJECTORS (SL-1 Series H)............................................................................1015 Injector Specifications..........................................................................1015 Injector Adjustment..............................................................................1015 INJECTOR OPERATION.......................................................................................1017 SYSTEM CHECKOUT......................................................................................1018 Lubrication Cycle Timer Check....................................................................1018 Lubrication Cycle Timer Adjustment...............................................................1019 PREVENTIVE MAINTENANCE INSPECTION....................................................................1019 10 Hour Lubrication System Inspection............................................................1019 100 Hour Inspection..............................................................................1019 250 Hour Inspection..............................................................................1019 500 Hour Inspection..............................................................................1020 1000 Hour Inspection.............................................................................1020 PUMP REBUILD.........................................................................................1021 Disassembly......................................................................................1021 Cleaning and Inspection..........................................................................1022 Assembly.........................................................................................1024 VENT VALVE REB UILD..................................................................................1025 Disassembly and Assembly.........................................................................1025 SYSTEM TROUBLESHOOTING CHART.........................................................................1026 SECTION P4 - MOTORIZED WHEEL MAINTENANCE SCHEDULE - INDEX....................................................1029 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................................................1031 AXLE BOX.............................................................................................1031 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................................................1032 ARMATURE AREA........................................................................................1032 AT TIRE CHANGE.......................................................................................1032 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................................................1032 GENERATOR/ALTERNATOR.................................................................................1033 GRID BLOWER MOTOR....................................................................................1033 CONTROL EQUIPMENT CHECKS.............................................................................1033 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................................................1034 VEHICLE OPERATIONS TESTS.............................................................................1034 SECTION R - SYSTEM SCHEMATICS - INDEX............................................................................1035 HYDRAULIC BRAKE SYSTEM SCHEMATIC.............................................................................1037 HYDRAULIC SYSTEM SCHEMATIC...................................................................................1038 ELECTRICAL SCHEMATIC.........................................................................................1039
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
