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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30431, A30432, A30460, A30461, A30463, A30464, & A30467 – A30469) – PDF Download
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- KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30431, A30432, A30460, A30461, A30463, A30464, & A30467 – A30469
- PUBLICATION NUMBER:CEBM026100
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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30431, A30432, A30460, A30461, A30463, A30464, & A30467 – A30469)
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30431, A30432, A30460, A30461, A30463, A30464, & A30467 – A30469) – PDF DOWNLOAD:
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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30431, A30432, A30460, A30461, A30463, A30464, & A30467 – A30469)
- 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.
TABLE OF CONTENTS:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30431, A30432, A30460, A30461, A30463, A30464, & A30467 – A30469)
COVER ..................................................................................................... 1 FOREWORD................................................................................................... 5 TABLE OF CONTENTS.......................................................................................... 7 SECTION A GENERAL INFORMATION INDEX........................................................................ 9 MAJOR COMPONENT DESCRIPTION............................................................................ 11 SPECIFICATIONS..................................................................................... 13 Komatsu SSA16V159.............................................................................. 13 SECTION A3 GENERAL SAFETY AND OPERATION INDEX.......................................................... 15 GENERAL SAFETY AND OPERATION....................................................................... 18 PERSONAL SAFETY................................................................................ 18 Safety Rules............................................................................... 18 Truck Safety Features...................................................................... 18 Clothing And Personal Items................................................................ 18 Unauthorized Modification.................................................................. 18 Leaving The Operator’s Seat................................................................ 18 Mounting And Dismounting................................................................... 19 Fire Extinguishers And First Aid Kits...................................................... 19 Precautions For High Temperature Fluids.................................................... 19 Asbestos Dust Hazard Prevention............................................................ 20 Fire Prevention For Fuel And Oil........................................................... 20 ROPS Precautions........................................................................... 20 Preventing Injury From Work Equipment...................................................... 20 Precautions For Optional Attachments....................................................... 20 Precautions When Starting The Machine...................................................... 21 PRECAUTIONS FOR TRUCK OPERATION................................................................ 21 Safety Is Thinking Ahead................................................................... 21 Safety At The Work Site.................................................................... 21 Fire Prevention............................................................................ 21 Preparing For Operation.................................................................... 21 Ventilation For Enclosed Areas............................................................. 21 Mirrors, Windows, And Lights............................................................... 22 In The Operator’s Cab - Before Starting The Engine......................................... 22 Seat Belts................................................................................. 22 OPERATING THE MACHINE.......................................................................... 22 Starting The Engine........................................................................ 22 Truck Operation - General.................................................................. 23 Traveling In The Truck..................................................................... 23 Precautions When Traveling In Reverse...................................................... 23 Traveling On Slopes........................................................................ 24 Ensuring Good Visibility................................................................... 24 Operating On Snow.......................................................................... 24 Avoid Damage To The Dump Body.............................................................. 24 Driving Near High-Voltage Cables........................................................... 24 When Loading The Truck..................................................................... 24 When Dumping............................................................................... 24 Working On Loose Ground.................................................................... 25 Parking The Machine........................................................................ 25 TOWING......................................................................................... 25 WORKING NEAR BATTERIES......................................................................... 25 Battery Hazard Prevention.................................................................. 25 Jump-Starting With Booster Cables.......................................................... 26 Jump Starting With Receptacles............................................................. 26 PRECAUTIONS FOR MAINTENANCE........................................................................ 27 BEFORE PERFORMING MAINTENANCE.................................................................. 27 Stopping The Engine Before Service......................................................... 27 Warning Tag................................................................................ 27 Proper Tools............................................................................... 27 Securing The Dump Body..................................................................... 27 DURING MAINTENANCE............................................................................. 28 Personnel.................................................................................. 28 Attachments................................................................................ 28 Working Under The Machine.................................................................. 28 Keeping The Machine Clean.................................................................. 28 Rules To Follow When Adding Fuel Or Oil.................................................... 28 Radiator Coolant Level..................................................................... 28 Use Of Lighting............................................................................ 28 Precautions With The Battery............................................................... 29 Handling High-Pressure Hoses............................................................... 29 Precautions With High-Pressure Oil......................................................... 29 Maintenance Near High Temperatures And High Pressures...................................... 29 Rotating Fan And Belts..................................................................... 29 Waste Materials............................................................................ 29 Use of Tie-Off Anchor During Maintenance and Repair........................................ 29 TIRES.......................................................................................... 30 Handling Tires............................................................................. 30 Tire Maintenance........................................................................... 31 Storing Tires After Removal................................................................ 31 ADDITIONAL JOB SITE RULES.......................................................................... 32 WHEN REPAIRS ARE NECESSARY......................................................................... 33 OPERATING INSTRUCTIONS............................................................................. 34 PREPARING FOR OPERATION........................................................................ 34 SAFETY IS THINKING AHEAD....................................................................... 34 WALK AROUND INSPECTION......................................................................... 34 ENGINE START-UP................................................................................ 38 AFTER ENGINE HAS STARTED....................................................................... 39 EMERGENCY STEERING SYSTEM...................................................................... 40 Operation.................................................................................. 40 Pre-Operation Testing...................................................................... 40 Additional Guidelines...................................................................... 41 MACHINE OPERATION SAFETY PRECAUTIONS........................................................... 41 LOADING........................................................................................ 42 HAULING........................................................................................ 42 PASSING........................................................................................ 43 DUMPING........................................................................................ 43 To Raise The Dump Body:.................................................................... 43 To Lower The Dump Body: (When dumping over a berm or into a crusher):...................... 44 To Lower The Dump Body (When dumping on flat ground):...................................... 44 TOWING......................................................................................... 45 Towing Procedure........................................................................... 45 SAFE PARKING PROCEDURES........................................................................ 46 ENGINE SHUTDOWN PROCEDURE...................................................................... 46 DELAYED ENGINE SHUTDOWN PROCEDURE.............................................................. 46 SUDDEN LOSS OF POWER........................................................................... 47 TROLLEY OPERATING INSTRUCTIONS................................................................. 48 AFTER THE ENGINE HAS STARTED............................................................... 48 OPERATING IN DIESEL MODE................................................................... 48 OPERATING IN TROLLEY LINE MODE............................................................. 49 GETTING ON LINE............................................................................ 49 Operating On Trolley................................................................... 51 GETTING OFF LINE........................................................................... 52 LINE STATUS SIGNALS........................................................................ 52 LINE STATUS SIGNAL MARKINGS................................................................ 53 TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION........................................... 53 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK............................... 54 OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS..................................... 54 TRUCK FAILURE WHILE ON TROLLEY............................................................. 54 SECTION A4 WARNINGS AND CAUTIONS...................................................................... 57 SECTION A5 TORQUE TABLES AND CONVERSION CHARTS ........................................................ 67 SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX.................................................. 77 SHORT TERM IDLE PERIODS............................................................................ 79 PREPARATION FOR STORAGE............................................................................ 80 REMOVAL FROM STORAGE............................................................................... 81 RECONDITIONING AN IDLE VEHICLE..................................................................... 82 ENGINE OPERATION................................................................................... 85 After The Engine Has Started................................................................... 85 ENGINE STORAGE..................................................................................... 86 Temporary Storage (30 Days Or Less)............................................................ 86 Extended Storage (More Than 30 Days)........................................................... 87 RESTORING AN ENGINE AFTER EXTENDED STORAGE......................................................... 88 ELECTRIC DRIVE TRUCKS.............................................................................. 89 Storing A Truck That Is Operational............................................................ 89 Storing A Truck That Is Not Operational........................................................ 90 Storing A Major Component...................................................................... 91 Periodic Inspections........................................................................... 91 Placing Equipment Into Service After Storage................................................... 91 SECTION B STRUCTURES INDEX................................................................................. 93 SECTION B2 STRUCTURAL COMPONENTS INDEX................................................................. 95 STRUCTURAL COMPONENTS.............................................................................. 97 LADDERS........................................................................................ 97 Removal.................................................................................... 97 Installation............................................................................... 97 GRILLE AND HOOD................................................................................ 98 Removal.................................................................................... 98 Installation............................................................................... 98 RIGHT-HAND DECK................................................................................ 98 Removal.................................................................................... 98 Installation............................................................................... 100 CENTER DECK.................................................................................... 100 LEFT-HAND DECK................................................................................. 101 Removal.................................................................................... 101 Installation............................................................................... 101 SECTION B3 DUMP BODY INDEX............................................................................. 103 DUMP BODY.......................................................................................... 105 Removal........................................................................................ 105 Installation................................................................................... 106 BODY SLING......................................................................................... 106 BODY PADS.......................................................................................... 107 BODY GUIDE......................................................................................... 107 Adjustment..................................................................................... 107 BODY POSITION INDICATOR............................................................................ 108 HOIST LIMIT SWITCH................................................................................. 108 ROCK EJECTORS...................................................................................... 108 Inspection..................................................................................... 108 SECTION B4 FUEL TANK INDEX............................................................................. 109 FUEL TANK.......................................................................................... 111 Removal........................................................................................ 111 Repair......................................................................................... 111 Cleaning....................................................................................... 111 Installation................................................................................... 112 FUEL GAUGE SENDER.................................................................................. 113 Removal........................................................................................ 113 Installation................................................................................... 113 LOW FUEL SENDER.................................................................................... 114 Removal........................................................................................ 114 Installation................................................................................... 114 TANK BREATHER VALVE................................................................................ 115 Removal........................................................................................ 115 Installation................................................................................... 115 Disassembly.................................................................................... 115 Assembly....................................................................................... 115 FUEL RECEIVER (WIGGINS QUICK FILL)................................................................. 116 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)............................................ 117 SECTION C ENGINE INDEX..................................................................................... 119 SECTION C2 POWER MODULE INDEX.......................................................................... 121 POWER MODULE....................................................................................... 123 GENERAL INFORMATION............................................................................ 123 POWER MODULE SERVICE........................................................................... 124 Removal.................................................................................... 124 Installation............................................................................... 128 SECTION C3 COOLING SYSTEM INDEX........................................................................ 131 COOLING SYSTEM..................................................................................... 133 RADIATOR....................................................................................... 133 Removal.................................................................................... 133 Service.................................................................................... 134 Installation............................................................................... 134 RADIATOR FILL PROCEDURE........................................................................ 135 RADIATOR REPAIR................................................................................ 135 Internal Inspection........................................................................ 135 External Cleaning.......................................................................... 136 Disassembly................................................................................ 136 Cleaning and Inspection.................................................................... 137 Assembly................................................................................... 137 Additional Service Information............................................................. 139 PRESSURE TESTING............................................................................... 139 COOLANT SYSTEM TROUBLESHOOTING................................................................. 139 SECTION C4 POWER TRAIN INDEX........................................................................... 141 POWER TRAIN........................................................................................ 143 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.................................................. 143 General Information........................................................................ 143 Removal.................................................................................... 143 ALTERNATOR INSTALLATION........................................................................ 145 Engine/Alternator Mating................................................................... 145 Alternator Measurement..................................................................... 145 Engine End Play Measurement................................................................ 146 Determining Shim Requirements.............................................................. 147 Installing Alternator On Engine............................................................ 148 ENGINE......................................................................................... 149 Removal.................................................................................... 149 Installation............................................................................... 149 SECTION C5 AIR CLEANERS INDEX.......................................................................... 151 AIR CLEANERS....................................................................................... 153 Service Checks................................................................................. 153 Filter Element Replacement..................................................................... 154 Main Filter Element Cleaning................................................................... 156 Precleaner Section............................................................................. 157 Cleaning Precleaner Tubes...................................................................... 157 Air Intake Troubleshooting..................................................................... 158 SECTION C7 FAN DRIVE CLUTCH INDEX...................................................................... 159 COMPONENTS......................................................................................... 160 Input.......................................................................................... 160 Output......................................................................................... 160 Stationary Components.......................................................................... 161 OPERATIONAL MODES.................................................................................. 162 Fully Engaged.................................................................................. 162 Modulated Variable Speed....................................................................... 162 Fully Released................................................................................. 163 Lubricating and Cooling Oil.................................................................... 164 MAINTENANCE........................................................................................ 165 TROUBLESHOOTING.................................................................................... 166 Preliminary Checks............................................................................. 166 FIELD CHECK DIAGNOSIS.............................................................................. 167 Preliminary Checks - Engine Off................................................................ 167 Check Clutch Release........................................................................... 167 Check Clutch Lock-up........................................................................... 168 Overheating.................................................................................... 168 Thermal Sensor and Solenoid Valve.............................................................. 169 On Truck Test.................................................................................. 169 Off Truck Test................................................................................. 169 FAN CLUTCH DISASSEMBLY INSTRUCTIONS................................................................ 174 REASSEMBLY OF THE FAN CLUTCH....................................................................... 181 INSPECTION OF PARTS................................................................................ 192 REBUILD TOOLS...................................................................................... 196 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX................................................... 197 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX.......................................................... 199 24VDC ELECTRIC SUPPLY SYSTEM....................................................................... 201 ELECTRICAL SYSTEM DESCRIPTION.................................................................. 201 BATTERIES...................................................................................... 201 Maintenance and Service.................................................................... 201 Troubleshooting............................................................................ 201 BATTERY CHARGING ALTERNATOR.................................................................... 203 24VDC ELECTRIC START SYSTEM........................................................................ 203 CRANKING MOTORS................................................................................ 203 Removal.................................................................................... 203 Installation............................................................................... 204 CRANKING MOTOR TROUBLESHOOTING................................................................. 204 Preliminary Inspection..................................................................... 205 No-Load Test............................................................................... 205 Interpreting Results of Tests.............................................................. 205 Disassembly................................................................................ 206 Cleaning and Inspection.................................................................... 206 Armature Servicing......................................................................... 207 Field Coil Checks.......................................................................... 209 Field Coil Removal......................................................................... 209 Solenoid Checks............................................................................ 209 Test....................................................................................... 209 Assembly................................................................................... 211 Pinion Clearance........................................................................... 212 MAGNETIC SWITCH................................................................................ 212 Coil Test.................................................................................. 212 Electric Start System Wiring Diagrams...................................................... 212 ENGINE PRELUB SYSTEM............................................................................... 213 OPERATION...................................................................................... 213 Pressure Switch............................................................................ 213 Suction Line............................................................................... 213 Outlet Line................................................................................ 213 Check Valve................................................................................ 213 Solenoid Timer............................................................................. 213 TROUBLESHOOTING PRELUB STARTER CIRCUIT............................................................. 215 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX.................................................... 219 24VDC ELECTRICAL SYSTEM COMPONENTS................................................................. 221 PASSENGER SEAT BASE COMPARTMENT................................................................ 221 COMPONENTS..................................................................................... 221 Taillight Resistor Diode Assemblies........................................................ 221 Inclinometer............................................................................... 221 Brake Warning Buzzer (BWB)................................................................. 221 Lubrication System Timer................................................................... 221 Three Minute Idle Timer Components......................................................... 221 Three Minute Idle Timer.................................................................... 223 Idle Timer Relay........................................................................... 223 Three Minute Idle Contactor................................................................ 223 Three Minute Idle Circuit Test............................................................. 223 Data Store Button.......................................................................... 223 Komatsu Engine Quantum Connector (Not Used)................................................ 223 Komatsu Engine Cense Connector............................................................. 223 STATEX III Propulsion System Diagnostic Connector.......................................... 223 Modular Mining Port (Optional)............................................................. 223 Alarm Indicating Device (AID) System....................................................... 224 Diode Matrix (Without Sound)............................................................... 224 Diode Matrix (With Sound).................................................................. 225 Hot Switch Inverter........................................................................ 225 Hot Switch Inverter Card (Slot 4) (Not Used)............................................... 225 Temperature................................................................................ 225 Oil Level.................................................................................. 225 Temperature and Latch...................................................................... 225 Coolant Level/Flasher...................................................................... 226 Lamp Test.................................................................................. 226 BATTERY EQUALIZER BOX.......................................................................... 226 Troubleshooting............................................................................ 226 BODY-UP SWITCH................................................................................. 227 Adjustment................................................................................. 227 Service.................................................................................... 227 HOIST LIMIT SWITCH............................................................................. 228 Adjustment................................................................................. 228 Service.................................................................................... 228 24-VOLT RELAY AND DIODE BOARDS................................................................. 228 RELAY BOARDS................................................................................... 229 Description................................................................................ 229 SERVICE........................................................................................ 229 To Replace A Relay:........................................................................ 229 To Replace A Circuit Breaker:.............................................................. 229 To Replace A Circuit Panel Card............................................................ 230 Relay Board Components..................................................................... 230 Installing Additional Circuits............................................................. 231 DIODE BOARD 1.............................................................................. 232 Diode Testing.............................................................................. 232 CIRCUIT BREAKERS............................................................................... 234 SECTION D10 BATTERY CHARGING ALTERNATOR INDEX.......................................................... 235 BATTERY CHARGING SYSTEM............................................................................ 239 BATTERY CHARGING SYSTEM........................................................................ 239 ELECTRICAL SYSTEM DESCRIPTION.............................................................. 239 CHARGE VOLT AND AMP VALUES................................................................. 239 BATTERY.................................................................................... 239 Maintenance and Service................................................................ 239 Troubleshooting........................................................................ 240 Undercharging.......................................................................... 240 Overcharging........................................................................... 240 Corrosion.............................................................................. 240 Acid Levels............................................................................ 240 Non-Use or Storage..................................................................... 240 Freezing............................................................................... 241 BATTERY CHARGING ALTERNATOR.................................................................... 242 GENERAL INFORMATION........................................................................ 242 General Description.................................................................... 242 Terminal Identification and Location................................................... 243 Battery Positive (B+).................................................................. 243 Battery Negative (B-).................................................................. 243 DC Output (D+)......................................................................... 243 AC Output (R).......................................................................... 243 Regulator Harness Plug Identification.................................................. 243 Alternator Specifications.............................................................. 243 Performance Curve...................................................................... 243 Battery/Alternator Terminology......................................................... 244 WIRING DIAGRAM............................................................................. 246 DIMENSIONS AND TORQUE VALUES............................................................... 247 PERIODIC MAINTENANCE....................................................................... 248 TESTING........................................................................................ 248 GENERAL INFORMATION........................................................................ 248 Troubleshooting Alternator (On-Truck).................................................. 248 Equipment Required..................................................................... 248 Preliminary Checks..................................................................... 248 Test Set-up............................................................................ 250 Test Procedure......................................................................... 251 REGULATOR TESTING.......................................................................... 252 Regulator Bypass Test (No Output)...................................................... 252 Regulator Bypass Test (Amp Rating)..................................................... 253 BENCH TESTING.............................................................................. 254 Equipment.............................................................................. 254 Identification Record.................................................................. 254 Advanced Troubleshooting............................................................... 254 Bench Test 1: No-Load Test............................................................. 254 Bench Test 2: Full Load Test........................................................... 255 Bench Test 3: Regulator Bypass Test.................................................... 255 STATIC TESTING............................................................................. 256 Equipment.............................................................................. 256 Identification Record.................................................................. 256 Regulator Tester....................................................................... 256 Check For Shorted Power Transistor..................................................... 256 Circuit Tests.......................................................................... 257 FIELD COIL TESTS........................................................................... 258 Field Coil Test 1: Check for Open or Shorted Field Coil................................ 258 Field Coil Test 2: Check For Grounded Field Coil....................................... 258 STATOR TESTS............................................................................... 259 Stator Test 1: Check For Stator-To-Stator Continuity................................... 259 Stator Test 2: Check For Grounded Stators.............................................. 260 THERMAL SWITCH TEST........................................................................ 260 Initial Test........................................................................... 260 Verifying a Faulty Thermal Switch...................................................... 261 TROUBLESHOOTING TIPS....................................................................... 262 ALTERNATOR..................................................................................... 266 ALTERNATOR REPAIR.......................................................................... 266 Removal................................................................................ 266 Installation........................................................................... 268 Special Tools and Lubricants........................................................... 268 Epoxy Adhesive......................................................................... 269 Liquid Threadlockers................................................................... 269 Elastoplastic Silicone Resin........................................................... 269 ALTERNATOR EXPLODED VIEW................................................................... 271 ALTERNATOR DISASSEMBLY..................................................................... 273 Regulator Removal...................................................................... 273 Fan Removal............................................................................ 274 Pulley Removal......................................................................... 275 Anti-Drive End Housing Removal......................................................... 275 Anti-Drive End Rotor Removal........................................................... 277 Drive End Housing Removal.............................................................. 279 Drive End Rotor Removal................................................................ 285 Field Coil Removal..................................................................... 286 Drive End and/or Anti-Drive End Stator Removal......................................... 288 CLEANING AND INSPECTION.................................................................... 290 ALTERNATOR ASSEMBLY........................................................................ 290 Anti-Drive End Stator Installation..................................................... 290 Drive End Stator Installation.......................................................... 292 Field Coil Installation................................................................ 295 Drive End Bearing Installation......................................................... 297 Drive End Rotor Installation........................................................... 299 Rotor and Rotor Shaft Installation..................................................... 299 Drive End Housing Installation......................................................... 300 Anti-Drive End Rotor Installation...................................................... 304 Anti-Drive End Housing Installation.................................................... 305 Regulator Installation................................................................. 308 THERMAL SWITCH............................................................................. 309 Removal................................................................................ 309 Installation........................................................................... 311 SUPPORT STAND.............................................................................. 311 SECTION D35 PAYLOAD METER III INDEX.................................................................... 313 Introduction....................................................................................... 318 Data Summary................................................................................... 318 Data Gathering................................................................................. 318 COMPONENT DESCRIPTION.............................................................................. 319 System Diagram................................................................................. 319 Suspension Pressure Sensors.................................................................... 319 Inclinometer................................................................................... 319 Operator Display............................................................................... 319 Operator Switch................................................................................ 320 Speed Input.................................................................................... 320 Body-Up Switch................................................................................. 320 Brake Lock Switch.............................................................................. 320 Payload Meter.................................................................................. 320 Communications Ports........................................................................... 320 Key Switch Input............................................................................... 321 Payload Meter Power............................................................................ 321 Load Lights.................................................................................... 321 Wiring and Termination......................................................................... 322 TCI Outputs.................................................................................... 322 OPERATOR’S DISPLAY AND SWITCH...................................................................... 323 Reading the Speedometer........................................................................ 323 Reading the Load Display....................................................................... 323 Using the Operator ID.......................................................................... 323 Using the Load and Ton Counter................................................................. 323 Total Ton Counter.............................................................................. 323 Total Load Counter............................................................................. 324 Clearing the Counters.......................................................................... 324 Viewing Live Sensor Data....................................................................... 324 Other Display Messages......................................................................... 324 PAYLOAD OPERATION & CALCULATION.................................................................... 325 Description of Haul Cycle States............................................................... 325 Haul Cycle Description......................................................................... 325 Load Calculation............................................................................... 326 Carry Back..................................................................................... 326 Measurement Accuracy........................................................................... 326 SOURCES FOR PAYLOAD ERROR.......................................................................... 326 Payload Error.................................................................................. 326 Loading Conditions............................................................................. 327 Pressure Sensors............................................................................... 327 Swingloads..................................................................................... 327 Speed and Distance............................................................................. 327 HAUL CYCLE DATA.................................................................................... 327 Haul Cycle Warning Flags....................................................................... 329 Frame Torque Data.............................................................................. 330 Sprung Weight Data............................................................................. 330 Maximum Speed Data............................................................................. 330 Alarm Records.................................................................................. 330 Fault Code Data................................................................................ 331 PC SOFTWARE OVERVIEW............................................................................... 332 System Configuration........................................................................... 332 Installing the PLMIII Software................................................................. 332 DOWNLOADING DATA................................................................................... 333 PLM III SYSTEM CONFIGURATION....................................................................... 334 Starting Communications........................................................................ 334 Displayed Payload Units........................................................................ 334 Time Units..................................................................................... 334 Connection Menu................................................................................ 334 Connecting to the Payload Meter................................................................ 335 Configure the Payload Meter.................................................................... 335 Setting the Date and Time...................................................................... 335 Setting the Truck Type......................................................................... 336 Setting the Gauge Display Units................................................................ 336 Setting the Frame Serial Number................................................................ 336 Setting the Truck Number....................................................................... 336 Setting the Komatsu Distributor................................................................ 336 Setting the Komatsu Customer................................................................... 336 Setting the Overload Speed Limit Function...................................................... 337 Clean Truck Tare............................................................................... 338 Inclinometer Calibration....................................................................... 338 DATA ANALYSIS...................................................................................... 339 Creating a Query............................................................................... 339 Sorting on Truck Unit Number................................................................... 339 Sorting on Truck Type.......................................................................... 339 Sorting on Date Range.......................................................................... 340 Sorting on Time Range.......................................................................... 340 Payload Detail Screen.......................................................................... 341 Creating Reports............................................................................... 341 Summary - one page report...................................................................... 342 Detailed - multi-page report................................................................... 342 Creating Graphs................................................................................ 343 Exporting Data................................................................................. 343 CSV Export..................................................................................... 343 Compressed..................................................................................... 344 Importing Data................................................................................. 345 Deleting Haul Cycle Records.................................................................... 345 Viewing Alarms................................................................................. 346 Deleting Alarm Records......................................................................... 346 TROUBLESHOOTING SECTION............................................................................ 347 TROUBLESHOOTING................................................................................ 347 Viewing Active Alarms...................................................................... 347 Real-Time Data Display..................................................................... 347 Testing the Payload Lights................................................................. 347 Creating Log Files of Inputs............................................................... 348 Daily Inspections.......................................................................... 348 Periodic Maintenance....................................................................... 348 Abnormal Displays at Power-Up.............................................................. 349 No Payload Display When Key Switch is Turned ON............................................ 350 No Display on Speedometer.................................................................. 351 No Display on Operator Display............................................................. 351 No Communications With PC.................................................................. 352 Load Lights Don’t Light During Loading..................................................... 353 Load Lights Remain ON...................................................................... 354 Load Lights Remain ON During Dumping....................................................... 354 Display Doesn't Clear When The Load Is Dumped.............................................. 354 Calibration Problems....................................................................... 355 Alarm 1 - Left Front Pressure High......................................................... 356 Alarm 2 - Left Front Pressure Low.......................................................... 356 Troubleshoot Wiring to Left Front Suspension............................................... 356 Alarm 3 - Right Front Pressure High........................................................ 357 Alarm 4 - Right Front Pressure Low......................................................... 357 Troubleshoot Wiring to Right Front Suspension.............................................. 357 Alarm 5 -Left Rear Pressure High........................................................... 358 Alarm 6 - Left Rear Pressure Low........................................................... 358 Troubleshoot Wiring to Left Rear Suspension................................................ 358 Alarm 7 - Right Rear Pressure High......................................................... 359 Alarm 8 - Right Rear Pressure Low.......................................................... 359 Troubleshoot Wiring to Right Rear Suspension............................................... 359 Alarm 9 - Inclinometer High................................................................ 360 Alarm 10 - Inclinometer Low................................................................ 360 Troubleshoot Inclinometer Wiring........................................................... 360 Alarm 13 - Body Up Input Failure........................................................... 361 Alarm 16 - Memory Write Failure............................................................ 362 Alarm 17 - Memory Read Failure............................................................. 362 Alarm 18................................................................................... 362 Alarm 19................................................................................... 362 Alarm 22................................................................................... 362 Operator Switch Doesn't Work............................................................... 363 Alarm 26 - User Switch Fault - SELECT...................................................... 363 Alarm 27 - User Switch Fault - SET......................................................... 363 Connector Map.............................................................................. 364 Connectors................................................................................. 365 General Description........................................................................ 366 Tools Required............................................................................. 366 Checkout Procedure......................................................................... 366 PLMIII CHECKOUT PROCEDURE CONFIRMATION......................................................... 370 Flashburn Programming...................................................................... 370 Confirmation Checklist..................................................................... 372 SECTION E ELECTRICAL PROPULSION INDEX...................................................................... 373 SECTION E2 ELECTRICAL PROPULSION COMPONENTS............................................................ 375 ELECTRICAL PROPULSION COMPONENTS................................................................... 379 GENERAL SYSTEM DESCRIPTION..................................................................... 379 CONTROL SYSTEM................................................................................. 379 System Operation............................................................................... 380 FL275 Panel.................................................................................... 381 CARD REPLACEMENT............................................................................... 382 Removal........................................................................................ 382 Installation................................................................................... 382 Card Repair.................................................................................... 382 Panel Wiring................................................................................... 382 COMPUTER DESCRIPTION........................................................................... 383 Microprocessor................................................................................. 383 Download Capability............................................................................ 383 SOFTWARE....................................................................................... 383 Base Monitor Program........................................................................... 383 Runtime Monitor Program - OBJ Running Code..................................................... 383 Configuration Software - CFG................................................................... 384 PTU - Portable Test Unit Code.................................................................. 384 System Regulation.............................................................................. 384 Propulsion..................................................................................... 385 Retarding...................................................................................... 385 TWO-DIGIT DISPLAY PANEL........................................................................ 386 The Coded Number............................................................................... 386 Events......................................................................................... 386 Frames......................................................................................... 387 Windows........................................................................................ 387 System Categories.............................................................................. 387 Limits On Resetting Faults..................................................................... 387 NA Faults...................................................................................... 388 Event Sequence................................................................................. 388 Resetting Events............................................................................... 388 Event Descriptions............................................................................. 388 Subcode Descriptions........................................................................... 388 2-DIGIT DISPLAY PANEL SUBCODES................................................................. 396 PORTABLE TEST UNIT (PTU)....................................................................... 399 DESCRIPTION.................................................................................... 399 Operational Hints.............................................................................. 399 SOFTWARE INSTALLATION PREPARATION.............................................................. 400 HARD DISK SPACE REQUIREMENTS................................................................... 400 SOFTWARE INSTALLATION ON PTU................................................................... 400 PTU/Truck Communication Problems............................................................... 401 THE MAIN MENU.................................................................................. 402 Quit Menu...................................................................................... 402 PTU Talk To Truck.............................................................................. 402 View PTU Saved Files........................................................................... 402 List Stat Data Files........................................................................... 402 Truck Setup (CFG).............................................................................. 402 Select Truck Setup............................................................................. 402 Update CFG Version............................................................................. 402 Change PTU Password............................................................................ 402 CONFIGURATION (CFG) FILE CONVERSION............................................................ 404 Conversion Procedure........................................................................... 404 Convert Old CFG files for New software......................................................... 405 STATEX CONFIGURATION FILES..................................................................... 408 0) Source Directory: . . ...................................................................... 408 1) Select A Truck Configuration . . ........................................................... 409 2) View Truck Configuration: Data Curves . . .................................................. 410 3) Change/View Serial and Model Numbers . . ................................................... 411 4) View Options . . ........................................................................... 411 5) Change/View Truck Specifics . . ............................................................ 413 6) Change/View Overspeeds . . ................................................................. 415 7) Save a Truck Configuration, filename: . . .................................................. 416 8) Save Directory: . . ........................................................................ 417 CHANGE PTU PASSWORD............................................................................ 418 PROGRAMMING THE TRUCK.......................................................................... 419 Connect PTU to the Truck....................................................................... 419 Select Configuration File...................................................................... 419 Activate The PTU Mode.......................................................................... 419 Check Object Code Version...................................................................... 420 Download Configuration Files................................................................... 421 Date And Time.................................................................................. 422 Event Data..................................................................................... 423 Statistical Data............................................................................... 425 View Counters.................................................................................. 425 View Profiles.................................................................................. 425 Upload Statistical Data To A File.............................................................. 425 Statistical Data Codes - Counters.............................................................. 426 STATISTICAL DATA CODES - COUNTERS.............................................................. 427 STATISTICAL DATA CODES - PROFILES.............................................................. 432 TRUCK SPECIFIC INFORMATION..................................................................... 436 Temporary Truck Settings....................................................................... 437 MISCELLANEOUS FEATURES......................................................................... 438 Saving Data.................................................................................... 438 PTU Abbreviations.............................................................................. 439 Other Menu Selections.......................................................................... 439 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS................................................. 440 ALTERNATOR..................................................................................... 440 ELECTRIC WHEEL MOTORS.......................................................................... 440 RETARDING GRIDS................................................................................ 440 ELECTRONIC ACCELERATOR AND RETARD PEDALS....................................................... 440 Removal........................................................................................ 440 Installation................................................................................... 440 Disassembly.................................................................................... 441 Reassembly..................................................................................... 441 COOLING BLOWER WARNING SYSTEM.................................................................. 441 Operation...................................................................................... 441 Test........................................................................................... 441 Removal........................................................................................ 442 Installation................................................................................... 442 ELECTRICAL CONTROL CABINET..................................................................... 443 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS......................................... 448 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III............................................. 449 SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE............................................ 451 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.................................................... 455 GENERAL INFORMATION................................................................................ 455 COMMUNICATIONS PORT CHECK.......................................................................... 456 PTU Hookup......................................................................................... 456 4.0 SEQUENCE TESTS - (ENGINE NOT ON)............................................................... 457 Preparation and Setup.............................................................................. 457 CONTROL SYSTEM SELF-TEST........................................................................... 458 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT........................................................... 458 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT............................................................. 459 PTU Setup.......................................................................................... 459 4.3 REVERSER AND PROPULSION CONTACTORS CHECK....................................................... 460 4.4 NOT USED....................................................................................... 461 4.5 RETARD CONTACTORS OPERATION CHECK.............................................................. 461 4.6 GROUND FAULT SENSING CHECK..................................................................... 461 4.7 GROUND FAULT IN RETARD OPERATION CHECK......................................................... 462 4.8 OVERRIDE OPERATION CHECK....................................................................... 462 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK.............................................................. 463 4.10 OVERSPEED RETARD OPERATION CHECK.............................................................. 463 4.11 HOIST INTERLOCK OPERATION CHECK............................................................... 464 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK...................................................... 464 Return to Main Menu................................................................................ 464 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL........................................... 465 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.................................................. 465 5.2 DIGITAL INPUT CHECKS........................................................................... 466 5.3 DIGITAL OUTPUT CHECKS.......................................................................... 467 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL................................................... 471 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU....................................................... 471 6.2 ANALOG INPUT CHECKS............................................................................ 472 6.3 FREQUENCY INPUT CHECKS......................................................................... 476 Return to Main Menu................................................................................ 477 7.0 SPEED EVENT CHECKS............................................................................. 477 Preparation and Setup.............................................................................. 477 Setup PTU.......................................................................................... 477 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK........................................ 478 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK............................. 478 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK............................ 478 7.4 OTHER SPEED EVENTS CHECKS...................................................................... 478 Return to Main Menu................................................................................ 478 8.0 RETARD SPEED CONTROL SYSTEM CHECK.............................................................. 479 Preparation and Setup.............................................................................. 479 Setup PTU.......................................................................................... 479 8.1 OVERSPEED PICKUP AND DROPOUT CHECK............................................................. 479 8.2 RETARD POT MAXIMUM SETTING CHECK............................................................... 479 8.3 RETARD POT MINIMUM SETTING CHECK............................................................... 479 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL............................................. 480 Return to Main Menu................................................................................ 480 9.0 LOAD TEST USING TRUCK RETARD GRIDS............................................................. 480 Setup and Preparation.............................................................................. 480 PTU Setup.......................................................................................... 480 9.1 LOAD TEST...................................................................................... 481 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING........................................................ 481 Setup PTU.......................................................................................... 481 10.1 RETARD CHECK.................................................................................. 482 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT................................................... 483 11.1 BRAKE SYSTEM INTERLOCKS CHECK................................................................. 483 Preparation........................................................................................ 483 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT........................................................ 483 11.3 SYNC TRANSFORMER CHECKOUT..................................................................... 484 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT.................................................... 484 11.5 BATTERY BOOST ADJUSTMENT...................................................................... 484 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST................................................... 484 11.7 MOTOR ROTATION TEST........................................................................... 485 11.8 GROUND FAULT CHECKS........................................................................... 485 12.0 MISCELLANEOUS CHARTS.......................................................................... 486 12.1 WHEEL MOTOR GEAR RATIOS....................................................................... 486 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS................................................................ 487 12.3 ENGINE OPTIONS................................................................................ 488 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX............................................................ 489 SECTION G2 TIRES AND RIMS INDEX........................................................................ 491 GENERAL INFORMATION................................................................................ 493 TIRES.............................................................................................. 493 Handling Tires................................................................................. 493 Tire Maintenance............................................................................... 494 Storing Tires After Removal.................................................................... 494 FRONT TIRES AND RIMS............................................................................... 495 Removal........................................................................................ 495 Installation................................................................................... 496 REAR TIRES AND RIMS................................................................................ 497 Removal........................................................................................ 497 Installation................................................................................... 498 RIM............................................................................................ 499 Tire Removal................................................................................... 499 RIM AND TIRE PREPARATION........................................................................... 500 LUBRICANTS......................................................................................... 500 TIRE INSTALLATION.................................................................................. 501 SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX........................................................... 503 FRONT WHEEL HUB AND SPINDLE........................................................................ 505 WHEEL HUB AND SPINDLE ASSEMBLY................................................................. 505 Removal.................................................................................... 505 Installation............................................................................... 507 Disassembly................................................................................ 508 Cleaning and Inspection.................................................................... 509 Assembly................................................................................... 509 Wheel Bearing Adjustment (Spindle Vertical)................................................ 512 Wheel Bearing Adjustment (Tire Mounted).................................................... 513 STEERING CYLINDERS AND TIE ROD................................................................. 517 Spherical Bearing Wear Limits.............................................................. 517 Removal.................................................................................... 518 Installation............................................................................... 520 Bearing Replacement........................................................................ 520 TOE-IN ADJUSTMENT.............................................................................. 521 SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX......................................................... 523 PIVOT PIN.......................................................................................... 525 Removal........................................................................................ 525 Installation................................................................................... 526 PIVOT EYE BEARING.................................................................................. 526 Disassembly.................................................................................... 526 Assembly....................................................................................... 527 PIVOT EYE REPAIR................................................................................... 527 Removal........................................................................................ 527 Disassembly.................................................................................... 527 Bushing (New).................................................................................. 527 Pivot Eye Bore (New)........................................................................... 527 Assembly....................................................................................... 527 Installation................................................................................... 528 ANTI-SWAY BAR...................................................................................... 528 Removal........................................................................................ 528 Installation................................................................................... 528 Disassembly.................................................................................... 529 Cleaning and Inspection........................................................................ 529 Assembly....................................................................................... 529 REAR AXLE HOUSING.................................................................................. 533 REAR AXLE HOUSING.............................................................................. 533 Removal.................................................................................... 533 Installation............................................................................... 533 WHEEL MOTOR.................................................................................... 534 Removal.................................................................................... 534 Cleaning and Inspection.................................................................... 534 Installation............................................................................... 535 WHEEL MOTOR GEAR OIL........................................................................... 538 Change/Filter The Gear case Oil............................................................ 538 Oil........................................................................................ 538 Remove And Clean Magnetic Plugs............................................................ 538 Flushing The Gearbox....................................................................... 538 Check Gear Case Oil Level.................................................................. 538 SECTION G5 REAR AXLE HOUSING.......................................................................... 531 SECTION H SUSPENSIONS INDEX................................................................................ 539 SECTION H2 FRONT SUSPENSION INDEX...................................................................... 541 Removal............................................................................................ 543 Installation....................................................................................... 545 Angle Advance Tightening Procedure................................................................. 546 Disassembly........................................................................................ 547 Cleaning and Inspection............................................................................ 548 Assembly (Bearing Only)............................................................................ 548 Suspension Assembly (Complete)..................................................................... 548 SUSPENSION PRESSURE TEST........................................................................... 550 SECTION H3 REAR SUSPENSIONS INDEX...................................................................... 553 Removal............................................................................................ 556 Installation....................................................................................... 558 Disassembly........................................................................................ 558 Cleaning and Inspection............................................................................ 559 Assembly........................................................................................... 559 SUSPENSION PRESSURE TEST........................................................................... 561 SECTION H4 OILING AND CHARGING PROCEDURES INDEX........................................................ 563 GENERAL............................................................................................ 565 EQUIPMENT LIST..................................................................................... 565 Hydrair® Charging Kit.......................................................................... 565 Installation of Charging Kit................................................................... 565 Removal of Charging Kit........................................................................ 566 Support Blocks For Oiling and Charging Dimensions.............................................. 566 FRONT SUSPENSION................................................................................... 567 Front Suspension Oiling........................................................................ 567 Front Suspension Nitrogen Charging............................................................. 568 REAR SUSPENSION.................................................................................... 570 Rear Suspension Oiling......................................................................... 570 Rear Suspension Nitrogen Charging.............................................................. 572 SECTION J BRAKE CIRCUIT INDEX.............................................................................. 575 SECTION J2 BRAKE CIRCUIT INDEX......................................................................... 577 GENERAL DESCRIPTION................................................................................ 579 SERVICE BRAKE CIRCUIT.............................................................................. 579 SECONDARY BRAKING AND AUTOMATIC APPLY.............................................................. 581 PARKING BRAKE CIRCUIT.............................................................................. 581 Normal Operation (key switch on, engine on).................................................... 581 BRAKE LOCK CIRCUIT................................................................................. 582 WARNING CIRCUIT.................................................................................... 582 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX....................................................... 585 BRAKE CIRCUIT COMPONENT SERVICE.................................................................... 587 BRAKE VALVE.................................................................................... 587 Rebuild Criteria........................................................................... 587 Removal.................................................................................... 587 Installation............................................................................... 589 Disassembly................................................................................ 591 Cleaning and Inspection.................................................................... 593 ASSEMBLY....................................................................................... 593 Actuator Base Threaded Inserts............................................................. 593 Boot and Cap............................................................................... 593 Valve Body Seal Installation............................................................... 594 Regulator Sleeve O-Ring Installation....................................................... 595 Actuator Plunger O-Ring Installation....................................................... 595 Assembly of Valve.......................................................................... 595 DIFFERENTIAL PRESSURE SWITCH................................................................... 596 Disassembly................................................................................ 597 Cleaning and Inspection.................................................................... 597 Assembly................................................................................... 597 VALVE BENCH TEST AND ADJUSTMENT................................................................ 597 Test Set Up Procedure...................................................................... 599 Brake Valve Output Pressure Adjustment..................................................... 599 Differential Pressure Switch Test.......................................................... 600 Final Test and Adjustment.................................................................. 600 Installation Of Brake Pedal Actuator Assembly to Brake Valve............................... 601 HYDRAULIC BRAKE ACCUMULATORS................................................................... 603 Brake Accumulator Bleed-Down Procedure..................................................... 603 Removal.................................................................................... 603 Installation............................................................................... 605 Disassembly................................................................................ 605 Cleaning and Inspection.................................................................... 607 Assembly................................................................................... 607 Leak Testing............................................................................... 610 BRAKE ACCUMULATOR CHARGING..................................................................... 611 Temperature During Precharge............................................................... 613 ACCUMULATOR STORAGE............................................................................ 613 Installation............................................................................... 614 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX..................................................... 615 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................................. 617 EQUIPMENT REQUIRED............................................................................. 620 INITIAL SYSTEM SET-UP.......................................................................... 621 Parking Brake.............................................................................. 621 Service Brakes............................................................................. 622 Brake Lock/Secondary....................................................................... 622 Low Brake Pressure and Auto Apply.......................................................... 623 Reapplications............................................................................. 623 Differential Pressure Switch............................................................... 623 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...................................................... 625 The Brakes are Locked, Service, and/or Parking................................................. 625 Both Brake Circuits are Dragging............................................................... 625 One Brake Circuit is Dragging.................................................................. 625 Brakes are Not Going to Full Pressure.......................................................... 625 A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off......................... 625 Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released.... 626 Differential Pressure Warning Circuit is Not Operating......................................... 626 A Low Brake Pressure Warning Occurs When Brakes are Applied.................................... 626 Low Pressure Warning Circuit Not Operating Properly............................................ 626 Low Pressure Warning is On Even Though System Pressure is Correct.............................. 627 Low Pressure Warning Comes On and Pressure is Low.............................................. 627 A Squeal is Heard When Controller is Operated.................................................. 627 Output Pressure At Controller is Correct but Brakes are Not Applying........................... 627 Brake Pressures Drift Excessively While Pedal is Held Steady................................... 627 Oil is Leaking Around the Pedal Base........................................................... 627 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM....................... 627 CHECK-OUT PROCEDURE................................................................................ 628 HYDRAULIC BRAKE SYSTEM DATA SHEET.................................................................. 628 SECTION J5 FRONT DISC BRAKES INDEX..................................................................... 631 BRAKE CALIPER...................................................................................... 633 Removal........................................................................................ 633 Installation................................................................................... 634 Disassembly.................................................................................... 635 Cleaning and Inspection........................................................................ 635 Assembly....................................................................................... 637 BRAKE LINING....................................................................................... 637 Replacement.................................................................................... 637 FRONT SERVICE BRAKE BURNISHING..................................................................... 639 BRAKE BLEEDING PROCEDURE....................................................................... 640 REAR DISC BRAKES................................................................................... 643 REAR BRAKES.................................................................................... 643 CALIPER, DISC, AND PARKING BRAKE............................................................... 643 Removal.................................................................................... 643 Installation............................................................................... 644 CALIPER PISTON................................................................................. 646 Piston Assembly Removal.................................................................... 646 Inspection................................................................................. 646 Piston Assembly Installation............................................................... 647 FUNCTIONAL TEST OF PISTON ASSEMBLY............................................................. 648 Return Spring Force........................................................................ 648 Built-In Clearance......................................................................... 648 Grip Force................................................................................. 650 Grip Force Measurement..................................................................... 651 Spring Force Measurement................................................................... 653 Disassembly of Piston Assembly............................................................. 654 Assembly of Piston Assembly................................................................ 655 BENCH TEST..................................................................................... 655 BRAKE LINING................................................................................... 656 Replacement................................................................................ 656 SERVICE BRAKE BURNISHING........................................................................... 659 SAFETY PRECAUTIONS............................................................................. 659 Rear Brake Burnishing...................................................................... 660 BRAKE BLEEDING PROCEDURE....................................................................... 661 Spring Force Measurement................................................................... 662 SECTION J6 REAR BRAKES INDEX........................................................................... 641 SECTION J7 PARKING BRAKE INDEX......................................................................... 663 GENERAL INFORMATION................................................................................ 665 PARKING BRAKE CALIPER.............................................................................. 665 Lining Thickness Inspection.................................................................... 665 Removal........................................................................................ 666 Installation................................................................................... 666 Parking Brake Adjustment....................................................................... 667 Parking Brake Caliper Disassembly.............................................................. 668 Cleaning and Inspection........................................................................ 669 Parking Brake Caliper Assembly................................................................. 670 PARKING BRAKE LINING REPLACEMENT................................................................... 670 PARKING BRAKE BURNISH PROCEDURE.................................................................... 670 Lining Conditioning............................................................................ 670 BRAKE BLEEDING PROCEDURE........................................................................... 671 SECTION L HYDRAULIC SYSTEM INDEX........................................................................... 673 SECTION L2 HYDRAULIC SYSTEM OVERVIEW.................................................................. 675 HYDRAULIC SYSTEM OVERVIEW.......................................................................... 676 Hoist Circuit Operation........................................................................ 676 Steering, Brake and Pantograph Circuit Operation............................................... 676 Axle Blower System Operation................................................................... 676 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR.......................................................... 679 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................................. 681 HOIST PUMP..................................................................................... 681 Removal.................................................................................... 681 Installation............................................................................... 683 Disassembly................................................................................ 683 Inspection................................................................................. 686 Assembly................................................................................... 687 PISTON PUMP................................................................................ 692 Removal................................................................................ 692 Installation........................................................................... 693 Disassembly............................................................................ 695 Inspection of Parts.................................................................... 701 Assembly............................................................................... 703 AXLE BLOWER HYDRAULIC MOTOR........................................................................ 708 Removal........................................................................................ 708 Installation................................................................................... 708 Rear Axle Blower Housing....................................................................... 708 Disassembly................................................................................ 708 Assembly................................................................................... 709 Disassembly................................................................................ 711 Inspection................................................................................. 713 Assembly................................................................................... 714 Trouble Shooting........................................................................... 715 Hand Wheel Control............................................................................. 716 Disassembly................................................................................ 716 Assembly................................................................................... 716 HYDRAULIC TANK................................................................................. 718 Filling Instructions....................................................................... 718 Removal.................................................................................... 719 Installation............................................................................... 719 HYDRAULIC TANK STRAINER AND DIFFUSER........................................................... 720 Removal.................................................................................... 720 Inspect and Clean.......................................................................... 721 Installation............................................................................... 721 SECTION L4 STEERING CIRCUIT INDEX...................................................................... 723 STEERING CIRCUIT OPERATION......................................................................... 725 COMPONENT DESCRIPTION.............................................................................. 726 Steering Control Valve......................................................................... 726 Unloader Valve................................................................................. 727 Bleed-Down Manifold Valve...................................................................... 727 Flow Amplifier................................................................................. 732 FLOW AMPLIFIER SYSTEM OPERATION.................................................................... 733 No Steer....................................................................................... 733 Steering Left.................................................................................. 735 Steering Right................................................................................. 737 No Steer, External Shock Load.................................................................. 739 Steering Pump.................................................................................. 741 High Pressure Filter........................................................................... 741 Accumulators................................................................................... 741 Low Precharge Warning Switch................................................................... 741 SECTION L5 STEERING CONTROL VALVE INDEX................................................................ 743 Removal............................................................................................ 745 Installation....................................................................................... 746 STEERING CONTROL VALVE REBUILD..................................................................... 747 Disassembly.................................................................................... 747 Cleaning and Inspection........................................................................ 748 Assembly....................................................................................... 748 BRAKE / STEERING PUMP.............................................................................. 752 Removal........................................................................................ 752 Installation................................................................................... 754 Disassembly.................................................................................... 755 Inspection of Parts............................................................................ 755 Assembly....................................................................................... 757 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX..................................................... 759 STEERING CIRCUIT COMPONENT REPAIR.................................................................. 761 BLEED-DOWN MANIFOLD............................................................................ 761 Removal.................................................................................... 761 Installation............................................................................... 761 ACCUMULATOR.................................................................................... 762 Removal.................................................................................... 762 Installation............................................................................... 763 Disassembly................................................................................ 764 Cleaning and Inspection.................................................................... 764 Assembly................................................................................... 765 Leak Testing............................................................................... 766 STEERING ACCUMULATOR CHARGING.................................................................. 767 Temperature During Precharge............................................................... 770 ACCUMULATOR STORAGE............................................................................ 771 Installation............................................................................... 771 FLOW AMPLIFIER................................................................................. 772 Removal.................................................................................... 772 Installation............................................................................... 772 Disassembly................................................................................ 773 Assembly................................................................................... 776 STEERING CYLINDERS............................................................................. 777 Disassembly................................................................................ 777 Piston Seal and Bearing Installation....................................................... 777 Cylinder Assembly.......................................................................... 777 Test....................................................................................... 777 TROUBLESHOOTING CHART.............................................................................. 780 SECTION L7 HOIST CIRCUIT INDEX......................................................................... 785 HOIST CIRCUIT OPERATION............................................................................ 787 COMPONENT DESCRIPTION.............................................................................. 788 Hydraulic Tank................................................................................. 788 Hydraulic Pump................................................................................. 788 High Pressure Filter........................................................................... 788 Hoist Valve.................................................................................... 788 Hoist Pilot Valve.............................................................................. 789 Bleed-Down Manifold............................................................................ 790 Counterbalance Manifold........................................................................ 790 Hoist-Up Limit Solenoid........................................................................ 790 Pilot Operated Check Valve..................................................................... 790 HOIST VALVE OPERATION.............................................................................. 792 Float Operation................................................................................ 792 Power Up Operation (Figure 7-6)................................................................ 794 Hold Operation (Figure 7-7).................................................................... 796 Power Down Operation (Figure 7-8).............................................................. 798 Float Operation (Figure 7-9)................................................................... 800 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX........................................................ 803 HOIST VALVE........................................................................................ 805 Removal........................................................................................ 805 Installation................................................................................... 805 O-Ring Replacement............................................................................. 807 INLET SECTION...................................................................................... 808 Disassembly.................................................................................... 808 Cleaning and Inspection........................................................................ 809 Assembly....................................................................................... 809 REAR SPOOL SECTION (WORK PORTS).................................................................... 810 Disassembly.................................................................................... 810 Cleaning and Inspection........................................................................ 812 Assembly....................................................................................... 812 HOIST PILOT VALVE.................................................................................. 814 Removal........................................................................................ 814 Installation................................................................................... 814 Disassembly.................................................................................... 815 Cleaning and Inspection........................................................................ 816 Assembly....................................................................................... 816 HOIST UP LIMIT SOLENOID VALVE...................................................................... 817 HOIST CYLINDERS.................................................................................... 818 Removal........................................................................................ 818 Installation................................................................................... 819 Disassembly.................................................................................... 821 Cleaning and Inspection........................................................................ 822 SS1143 Tightening Tool - Assembly Drawing...................................................... 823 ASSEMBLY OF QUILL AND CYLINDER..................................................................... 823 Quill Installation............................................................................. 823 Installation Of Check Balls And Plugs In Quill................................................. 824 Assembly of Cylinder........................................................................... 826 Pressure Testing............................................................................... 827 COUNTERBALANCE MANIFOLD............................................................................ 827 SECTION L9 HIGH PRESSURE FILTERS INDEX................................................................. 829 HOIST CIRCUIT FILTER............................................................................... 831 Filter Element Replacement..................................................................... 831 Removal........................................................................................ 832 Installation................................................................................... 832 Indicator Switch............................................................................... 832 STEERING CIRCUIT FILTER............................................................................ 833 Filter Element Replacement..................................................................... 833 Removal........................................................................................ 834 Installation................................................................................... 834 Indicator Switch............................................................................... 834 INDICATOR SWITCH................................................................................... 834 Test Procedure................................................................................. 834 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE.............................................................. 837 HYDRAULIC CHECKOUT PROCEDURE....................................................................... 839 Initial Start Up and Flushing (Steps 5 - 22)................................................... 840 Component Checkout and Adjustment (Steps 23 - 34).............................................. 842 Adjustment Procedure for Hoist Counterbalance Cartridge Valve (Steps 34a-34l).................. 844 Counterbalance Valve Adjustment (Steps f & g):............................................. 846 Manifold reassembly (steps i through k):................................................... 846 Piston Pump and Axle Box Hydraulic Motor Adjustment (Steps 35 - 50)............................ 846 Oil Cleanliness Check.......................................................................... 847 Oil Sampling Location on Truck:............................................................ 847 Oil Sampling Process and Cleanliness Criteria:............................................. 847 DISABLED TRUCK DUMPING PROCEDURE............................................................... 848 HOOKUP..................................................................................... 848 DUMPING PROCEDURE.......................................................................... 848 Raising the Body:.......................................................................... 848 Lowering the Body:......................................................................... 849 SECTION M OPTIONS AND SPECIAL TOOLS INDEX.................................................................. 857 SECTION M4 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM INDEX.............................................. 859 SYSTEM ADJUSTMENT.................................................................................. 861 PUMP............................................................................................... 864 Removal............................................................................................ 864 Disassembly........................................................................................ 864 Inspection......................................................................................... 864 Assembly........................................................................................... 864 Installation....................................................................................... 864 BLOWER DRIVE MOTOR................................................................................. 867 Removal............................................................................................ 867 Disassembly........................................................................................ 867 Inspection Of Parts................................................................................ 868 Assembly........................................................................................... 869 Installation....................................................................................... 870 BLOWER BEARING REPAIR.............................................................................. 870 Removal........................................................................................ 870 Replacement.................................................................................... 870 Assembly....................................................................................... 871 AIR CLEANER........................................................................................ 871 Assembly....................................................................................... 871 Removal........................................................................................ 871 Assembly....................................................................................... 871 SECTION M7 HEATER OPTIONS INDEX........................................................................ 873 GENERAL INFORMATION................................................................................ 875 TROUBLESHOOTING.................................................................................... 875 HEATER ELEMENT..................................................................................... 875 Removal........................................................................................ 875 Installation................................................................................... 876 GENERAL............................................................................................ 877 Maintenance.................................................................................... 877 HEATING ELEMENT.................................................................................... 877 Removal........................................................................................ 877 Installation................................................................................... 878 THERMOSTAT......................................................................................... 878 Removal........................................................................................ 878 Installation................................................................................... 878 GENERAL INFORMATION................................................................................ 879 TROUBLESHOOTING.................................................................................... 879 HEATER ELEMENT..................................................................................... 879 Removal........................................................................................ 879 Installation................................................................................... 880 SECTION M8 SPECIAL TOOLS.............................................................................. 881 NITROGEN CHARGING VALVE............................................................................ 881 ROLL-OUT ASSEMBLY.................................................................................. 881 EYE BOLT........................................................................................... 881 OFFSET WRENCH...................................................................................... 882 TORQUE ADAPTER..................................................................................... 882 HANDLE............................................................................................. 882 SEAL INSTALLER..................................................................................... 882 SLEEVE ALIGNMENT TOOLS............................................................................. 883 QUICK DISCONNECT COUPLING.......................................................................... 883 HARNESS............................................................................................ 883 SEAL INSTALLATION RING............................................................................. 883 BELT TENSION TESTER................................................................................ 884 BELT ALIGNMENT TOOL................................................................................ 884 SOCKETS AND ADAPTERS............................................................................... 884 DUST CAPS.......................................................................................... 884 HYDRAULIC SYSTEM FLUSHING TOOLS.................................................................... 885 PAYLOAD DATA MANAGER............................................................................... 885 HYDRAULIC SYSTEM VACUUM PUMP....................................................................... 885 MISCELLANEOUS SERVICE TOOLS........................................................................ 886 BRAKE PISTON TOOL.................................................................................. 887 HIGH VOLTAGE TOOLS................................................................................. 890 2000 VDC METER..................................................................................... 890 GROUNDING STICKS................................................................................... 890 BODY PAD SPACER TOOL............................................................................... 891 SECTION M19 RADIATOR SHUTTERS INDEX.................................................................... 893 SECTION N OPERATOR'S CAB INDEX............................................................................. 903 SECTION N2 TRUCK CAB INDEX............................................................................. 905 TRUCK CAB.......................................................................................... 907 TRUCK CAB...................................................................................... 907 Description................................................................................ 907 Removal.................................................................................... 908 Installation............................................................................... 910 CAB DOOR....................................................................................... 910 Removal.................................................................................... 910 Installation............................................................................... 911 Door Adjustment............................................................................ 911 Door Jam Bolt Adjustment................................................................... 911 Door Handle Plunger Adjustment............................................................. 913 Replace Door Glass......................................................................... 914 Replace Door Window Regulator.............................................................. 918 Replace Door Handle or Latch Assembly...................................................... 918 Door and Door Hinge Seal Replacement....................................................... 919 Door Opening Seal Removal.................................................................. 919 Installation............................................................................... 919 GLASS REPLACEMENT.............................................................................. 920 Adhesive-Bonded Windows.................................................................... 920 Recommended Tools/Supplies................................................................. 920 Replacement Procedure...................................................................... 920 Windshield and Rear Glass.................................................................. 921 Removal.................................................................................... 921 Installation............................................................................... 922 Removal and Installation of Operator Seat...................................................... 923 Inspection................................................................................. 923 Removal.................................................................................... 923 Installation............................................................................... 923 Removal and Installation of Passenger Seat..................................................... 924 Removal.................................................................................... 924 Installation............................................................................... 924 SECTION N3 CAB COMPONENTS INDEX........................................................................ 925 WINDSHIELD WIPERS.................................................................................. 927 WIPER MOTOR REPLACEMENT........................................................................ 927 Removal.................................................................................... 927 Installation............................................................................... 927 WIPER ARM REPLACEMENT.......................................................................... 927 Removal.................................................................................... 927 Installation............................................................................... 928 WIPER LINKAGE REPLACEMENT...................................................................... 928 Removal.................................................................................... 928 Installation............................................................................... 929 WINDSHIELD WASHER.............................................................................. 929 Operation.................................................................................. 929 Service.................................................................................... 929 SEAT BELT...................................................................................... 930 Removal.................................................................................... 930 Installation............................................................................... 930 SECTION N4 OPERATOR COMFORT INDEX...................................................................... 933 HEATER/AIR CONDITIONER............................................................................. 937 CONTROLS....................................................................................... 937 Operation.................................................................................. 937 Heater/Air Conditioner Vents............................................................... 937 Defroster Vent Control Switch.............................................................. 937 Heat Control Switch........................................................................ 937 Temperature Control Knob................................................................... 937 Fan Control Knob........................................................................... 937 Heater/Air Conditioner Selector Switch..................................................... 937 COMPONENTS..................................................................................... 938 Circuit Breakers........................................................................... 938 Relays..................................................................................... 938 Heater Core................................................................................ 938 Fan Motor and Speed Control................................................................ 939 Test....................................................................................... 939 Actuators.................................................................................. 939 Test....................................................................................... 939 Cab Air Filter............................................................................. 940 AIR CONDITIONING SYSTEM............................................................................ 942 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES...................................................... 943 PRINCIPLES OF REFRIGERATION.................................................................... 943 Air Conditioning........................................................................... 943 Refrigeration - The Act of Cooling......................................................... 944 The Refrigeration Cycle.................................................................... 944 AIR CONDITIONER SYSTEM COMPONENTS.............................................................. 945 Compressor (Refrigerant Pump).............................................................. 945 Service Valves............................................................................. 945 Receiver-Drier............................................................................. 945 Condenser.................................................................................. 945 Expansion Block Valve...................................................................... 946 Accumulator................................................................................ 946 Evaporator................................................................................. 947 ELECTRICAL CIRCUIT............................................................................. 947 Thermostat................................................................................. 947 Compressor Clutch.......................................................................... 948 Trinary™ Switch............................................................................ 948 SYSTEM SERVICING............................................................................... 950 SERVICE TOOLS AND EQUIPMENT.................................................................... 951 Recovery/Recycle Station................................................................... 951 Leak Detector.............................................................................. 952 Service Valves............................................................................. 952 Vacuum Pump................................................................................ 952 Manifold Gauge Set......................................................................... 953 Low Side Gauge............................................................................. 953 High Side Gauge............................................................................ 953 Installing Manifold Gauge Set.............................................................. 954 Purging Air From Service Hoses............................................................. 954 SYSTEM PERFORMANCE TEST........................................................................ 955 SYSTEM OIL..................................................................................... 956 Handling and Reusing RPAG Oil.............................................................. 956 Oil Quantity............................................................................... 956 Checking System Oil........................................................................ 956 REFRIGERANT.................................................................................... 957 Recycled Refrigerant....................................................................... 957 Reclaimed Refrigerant...................................................................... 957 Refrigerant Quantity....................................................................... 958 R-134a Refrigerant Containers.............................................................. 958 SYSTEM LEAK TESTING............................................................................ 958 Electronic Leak Detector................................................................... 959 Tracer Dyes................................................................................ 959 Soap and Water............................................................................. 959 RECOVERING AND RECYCLING THE REFRIGERANT....................................................... 959 Performing the Recovery Cycle.............................................................. 959 Performing the Recycling Procedure......................................................... 960 Evacuating and Charging the A/C System..................................................... 960 SYSTEM REPAIR.................................................................................. 960 System Flushing............................................................................ 961 COMPONENT REPLACEMENT.......................................................................... 961 Hoses and Fittings......................................................................... 961 Lines...................................................................................... 961 Expansion Valve............................................................................ 962 Receiver-Drier............................................................................. 962 Thermostat................................................................................. 962 Compressor................................................................................. 962 Accumulator................................................................................ 963 Clutch..................................................................................... 963 Servicing the Compressor Clutch............................................................ 964 Pulley Removal............................................................................. 966 Clutch Coil Check.......................................................................... 966 Pulley Installation........................................................................ 967 Clutch Assembly Installation............................................................... 967 EVACUATING THE SYSTEM.......................................................................... 968 CHARGING THE A/C SYSTEM........................................................................ 970 AIR CONDITIONER DRIVE BELT..................................................................... 970 Pulley Alignment........................................................................... 970 Belt Tension............................................................................... 971 TROUBLESHOOTING................................................................................ 972 Preliminary Checks......................................................................... 972 Diagnosis of Gauge Readings and System Performance......................................... 973 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................................. 974 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM............................................... 980 SECTION N5 OPERATOR CONTROLS.......................................................................... 981 OPERATOR CONTROLS.................................................................................. 983 STEERING WHEEL AND CONTROLS.................................................................... 984 STEERING WHEEL............................................................................. 984 HORN BUTTON................................................................................ 984 TILT/TELESCOPE LEVER....................................................................... 984 MULTI-FUNCTION TURN SIGNAL SWITCH.......................................................... 984 Turn Signal Operation.................................................................. 985 High Beam Headlight Operation.......................................................... 985 Windshield Wiper Operation............................................................. 985 STEERING COLUMN............................................................................ 985 Removal................................................................................ 985 Inspection............................................................................. 986 Installation........................................................................... 986 PEDALS......................................................................................... 986 SERVICE BRAKE PEDAL........................................................................ 986 DYNAMIC RETARDER PEDAL..................................................................... 987 Optional - Dual Function/Single Pedal.................................................. 987 THROTTLE PEDAL............................................................................. 987 OVERHEAD PANEL CONTROLS AND COMPONENTS......................................................... 988 GRADE/SPEED WARNING CHART.................................................................. 988 RADIO SPEAKERS............................................................................. 988 WINDSHIELD WIPERS.......................................................................... 988 WARNING ALARM BUZZER....................................................................... 988 CAB RADIO.................................................................................. 988 WARNING LIGHTS DIMMER CONTROL.............................................................. 988 WARNING/STATUS INDICATOR LIGHT PANEL....................................................... 988 AIR CLEANER VACUUM GAUGES.................................................................. 988 CENTER CONSOLE................................................................................. 989 TRUCK CONTROLS............................................................................. 990 F-N-R Selector Switch.................................................................. 990 Hoist Control Lever.................................................................... 990 Trolley Master Control Lever........................................................... 990 CONSOLE SWITCHES AND CONTROLS.............................................................. 990 Cigarette Lighter...................................................................... 990 Window Control Switches................................................................ 990 Engine Shutdown Switch................................................................. 990 Override Switch........................................................................ 991 Retard Speed Control (RSC) Switch...................................................... 991 Retard Speed Control (RSC) Dial........................................................ 991 Statex III Download Port............................................................... 992 Engine Diagnostic Port (CENSE)......................................................... 992 Engine Diagnostic Connectors........................................................... 992 Data Storage Button.................................................................... 992 Passenger Seat......................................................................... 992 PAYLOAD METER.............................................................................. 993 Payload Meter Download Connector....................................................... 993 CAB CLIMATE CONTROL............................................................................ 994 HEATER/AIR CONDITIONER VENTS............................................................... 994 HEATER/AIR CONDITIONER CONTROLS AND VENTS.................................................. 994 Defroster Vent Control Switch.......................................................... 994 Heat Control Switch.................................................................... 994 Temperature Control Knob............................................................... 994 Fan Control Knob....................................................................... 994 Heater/Air Conditioner Vents........................................................... 994 OPERATOR SEAT.................................................................................. 995 ADJUSTMENT................................................................................. 995 INSTRUMENT PANEL............................................................................... 996 GENERAL INFORMATION........................................................................ 996 CONTROL SYMBOLS............................................................................ 996 CONTROL SWITCHES AND GAUGES................................................................ 997 Key Switch............................................................................. 998 Engine Shutdown Switch With Timer Delay................................................ 998 Fog Light Switch....................................................................... 998 Ladder Light Switch.................................................................... 998 Backup Light Switch.................................................................... 998 Panel Illumination Lights.............................................................. 998 Cab Air Conditioner/Heater Vents....................................................... 998 Engine Cold Weather Starting Aid Switch................................................ 998 Rotating Beacon Light Switch........................................................... 999 Heated Mirror Switch................................................................... 999 Wheel Brake Lock Switch................................................................ 999 Leakage Test Switch (Trolley Only)..................................................... 999 Parking Brake Switch................................................................... 999 Digital Tachometer..................................................................... 999 Right Turn Signal Indicator Light......................................................1000 High Beam Headlight Indicator Light....................................................1000 Left Turn Signal Indicator Light.......................................................1000 Digital Speedometer/Payload Meter Display..............................................1000 Voltmeter Gauge........................................................................1000 Engine Oil Pressure Gauge..............................................................1000 Engine Water Temperature Gauge.........................................................1000 Fuel Gauge.............................................................................1000 Engine Hourmeter.......................................................................1001 Headlight Switch.......................................................................1001 Panel Illumination Lights Dimmer Rheostat..............................................1001 Payload Meter Switch...................................................................1001 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL................................................1002 INDICATOR LIGHT FUNCTIONS..................................................................1003 High Hydraulic Oil Temperature.........................................................1003 Low Steering Pressure..................................................................1003 Low Accumulator Precharge Pressure Warning.............................................1003 Electric System Fault Warning..........................................................1004 Low Brake Pressure Indicator...........................................................1004 Low Hydraulic Tank Level...............................................................1004 Low Automatic Lubrication System Pressure..............................................1004 Circuit Breaker Tripped................................................................1004 Hydraulic Oil Filter...................................................................1004 Low Fuel Indicator.....................................................................1005 Parking Brake Indicator................................................................1005 Service Brake Indicator................................................................1005 Body Up Indicator......................................................................1005 Dynamic Retarding Indicator............................................................1005 Stop Engine Warning....................................................................1005 Backup Indicator.......................................................................1005 Engine Shutdown Timer Switch- Five Minute Idle.........................................1005 Retard Speed Control...................................................................1005 Service Engine Indicator (AEM).........................................................1006 High Wheel Motor Temperature Indicator.................................................1006 Blower Fault Warning...................................................................1006 Service Engine Indicator (CENSE).......................................................1006 Komatsu Engines w/Centry™ Fuel Control.................................................1006 Hazard Warning Light Switch............................................................1006 Lamp Test Switch/Centry™ Diagnostic Test Switch........................................1006 Backup Lights..........................................................................1010 Retard Lights..........................................................................1010 Brake Light............................................................................1010 Backup Alarm...........................................................................1010 CENTRY™ FUEL SYSTEM DIAGNOSTICS................................................................1011 GENERAL OPERATION..........................................................................1011 DETERMINING FAULT CODES....................................................................1011 EXITING THE DIAGNOSTICS MODE...............................................................1012 SECTION P LUBRICATION AND SERVICE INDEX....................................................................1013 SECTION P2 LUBRICATION AND SERVICE INDEX...............................................................1015 LUBRICATION AND SERVICE............................................................................1017 GENERAL INFORMATION............................................................................1017 HYDRAULIC TANK SERVICE.........................................................................1017 Adding Oil.................................................................................1017 COOLING SYSTEM.................................................................................1018 Radiator Filling Procedure.................................................................1018 RESERVE ENGINE OIL SYSTEM - (OPTIONAL).........................................................1018 Reserve Oil Tank Filling Procedure (Remote Fill)...........................................1018 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS....................................................1020 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)........................................1021 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................................1022 100 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................1022 250 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................1023 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)........................................1024 500 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................1025 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)........................................1026 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................1027 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................1028 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................1028 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................1029 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................1030 SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX..........................................................1031 AUTOMATIC LUBRICATION SYSTEM.......................................................................1033 GENERAL DESCRIPTION............................................................................1033 SYSTEM COMPONENTS..............................................................................1034 Filter Assembly............................................................................1034 Hydraulic Motor and Grease Pump............................................................1034 Reservoir..................................................................................1034 Fixed Pressure Reducing Valve..............................................................1034 Flow Control Valve.........................................................................1034 Solenoid Valve.............................................................................1035 Vent Valve.................................................................................1035 24VDC Lubrication Cycle Timer..............................................................1035 Time Delay Module..........................................................................1035 Pump Cutoff Pressure Switch................................................................1035 Unloader Valve.............................................................................1035 Pressure Switch............................................................................1035 Pressure Gauge.............................................................................1035 Manual Override Button.....................................................................1035 Injectors..................................................................................1035 SYSTEM OPERATION...............................................................................1038 Normal Operation...........................................................................1038 Pressure Failure Detection Circuits........................................................1039 GENERAL INSTRUCTIONS...........................................................................1040 LUBRICANT REQUIRED FOR SYSTEM..............................................................1040 SYSTEM PRIMING.............................................................................1040 LUBRICANT PUMP.............................................................................1041 Pump Housing Oil Level.................................................................1041 Pump Pressure Control..................................................................1041 FILTER AND RESERVOIR.......................................................................1041 Filter Assembly Element................................................................1042 INJECTORS (SL-1 Series H)..................................................................1042 Injector Specifications................................................................1042 Injector Adjustment....................................................................1042 INJECTOR OPERATION.................................................................................1044 SYSTEM CHECKOUT................................................................................1045 Lubrication Cycle Timer Check..............................................................1045 Lubrication Cycle Timer Adjustment.........................................................1046 PREVENTIVE MAINTENANCE INSPECTION..............................................................1046 10 Hour Lubrication System Inspection......................................................1046 100 Hour Inspection........................................................................1046 250 Hour Inspection........................................................................1046 500 Hour Inspection........................................................................1047 1000 Hour Inspection.......................................................................1047 PUMP REBUILD...................................................................................1048 Disassembly................................................................................1048 Cleaning and Inspection....................................................................1048 Assembly...................................................................................1050 VENT VALVE REBUILD.............................................................................1051 Disassembly and Assembly...................................................................1051 SYSTEM TROUBLESHOOTING CHART...................................................................1052 SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX..................................................1055 SECTION R SYSTEM SCHEMATICS...............................................................................1061 EF5755 BRAKE SCHEMATIC ................................................................................1063 EJ2730 HYDRAULIC SCHEMATIC ............................................................................1064 XS1000 ELECTRICAL SCHEMATIC ...........................................................................1065
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2 reviews for KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30431, A30432, A30460, A30461, A30463, A30464, & A30467 – A30469) – PDF Download
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Joey Rhys –
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Jones Santino –