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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30474, A30512 – A30517, & A30546-A30549) – PDF DOWNLOAD
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- KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30474, A30512 – A30517, & A30546-A30549
- PUBLICATION NUMBER:CEBM018301
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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30474, A30512 – A30517, & A30546-A30549)
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30474, A30512 – A30517, & A30546-A30549) – PDF DOWNLOAD:
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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30474, A30512 – A30517, & A30546-A30549)
- 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:A30474, A30512 – A30517, & A30546-A30549)
COVER ..................................................................................................... 1 FOREWORD................................................................................................... 5 TABLE OF CONTENTS.......................................................................................... 7 SECTION A GENERAL INFORMATION INDEX........................................................................ 9 SECTION A2 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...................................................................... 56 SECTION A5 TORQUE TABLES AND CONVERSION CHARTS ........................................................ 66 SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX.................................................. 76 SHORT TERM IDLE PERIODS............................................................................ 78 PREPARATION FOR STORAGE............................................................................ 79 REMOVAL FROM STORAGE............................................................................... 80 RECONDITIONING AN IDLE VEHICLE..................................................................... 81 ENGINE OPERATION................................................................................... 84 After The Engine Has Started................................................................... 84 ENGINE STORAGE..................................................................................... 85 Temporary Storage (30 Days Or Less)............................................................ 85 Extended Storage (More Than 30 Days)........................................................... 86 RESTORING AN ENGINE AFTER EXTENDED STORAGE......................................................... 87 ELECTRIC DRIVE TRUCKS.............................................................................. 88 Storing A Truck That Is Operational............................................................ 88 Storing A Truck That Is Not Operational........................................................ 89 Storing A Major Component...................................................................... 90 Periodic Inspections........................................................................... 90 Placing Equipment Into Service After Storage................................................... 90 SECTION B STRUCTURES INDEX................................................................................. 92 SECTION B2 STRUCTURAL COMPONENTS INDEX................................................................. 94 STRUCTURAL COMPONENTS.............................................................................. 96 LADDERS........................................................................................ 96 Removal.................................................................................... 96 Installation............................................................................... 96 GRILLE AND HOOD................................................................................ 97 Removal.................................................................................... 97 Installation............................................................................... 97 RIGHT-HAND DECK................................................................................ 97 Removal.................................................................................... 97 Installation............................................................................... 99 CENTER DECK.................................................................................... 99 LEFT-HAND DECK................................................................................. 100 Removal.................................................................................... 100 Installation............................................................................... 100 SECTION B3 DUMP BODY INDEX............................................................................. 102 DUMP BODY.......................................................................................... 104 Removal........................................................................................ 104 Installation................................................................................... 105 BODY SLING......................................................................................... 105 BODY PADS.......................................................................................... 106 BODY GUIDE......................................................................................... 106 Adjustment..................................................................................... 106 BODY POSITION INDICATOR............................................................................ 107 HOIST LIMIT SWITCH................................................................................. 107 ROCK EJECTORS...................................................................................... 107 Inspection..................................................................................... 107 SECTION B4 FUEL TANK INDEX............................................................................. 108 FUEL TANK.......................................................................................... 110 Removal........................................................................................ 110 Repair......................................................................................... 110 Cleaning....................................................................................... 110 Installation................................................................................... 111 FUEL GAUGE SENDER.................................................................................. 112 Removal........................................................................................ 112 Installation................................................................................... 112 LOW FUEL SENDER.................................................................................... 113 Removal........................................................................................ 113 Installation................................................................................... 113 TANK BREATHER VALVE................................................................................ 114 Removal........................................................................................ 114 Installation................................................................................... 114 Disassembly.................................................................................... 114 Assembly....................................................................................... 114 FUEL RECEIVER (WIGGINS QUICK FILL)................................................................. 115 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)............................................ 116 SECTION C ENGINE INDEX..................................................................................... 118 SECTION C2 POWER MODULE INDEX.......................................................................... 120 POWER MODULE....................................................................................... 122 GENERAL INFORMATION............................................................................ 122 POWER MODULE SERVICE........................................................................... 123 Removal.................................................................................... 123 Installation............................................................................... 127 SECTION C3 COOLING SYSTEM INDEX........................................................................ 130 COOLING SYSTEM..................................................................................... 132 RADIATOR....................................................................................... 132 Removal.................................................................................... 132 Service.................................................................................... 133 Installation............................................................................... 133 RADIATOR FILL PROCEDURE........................................................................ 134 RADIATOR REPAIR................................................................................ 134 Internal Inspection........................................................................ 134 External Cleaning.......................................................................... 135 Disassembly................................................................................ 135 Cleaning and Inspection.................................................................... 136 Assembly................................................................................... 136 Additional Service Information............................................................. 138 PRESSURE TESTING............................................................................... 138 COOLANT SYSTEM TROUBLESHOOTING................................................................. 138 SECTION C4 POWER TRAIN INDEX........................................................................... 140 POWER TRAIN........................................................................................ 142 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.................................................. 142 General Information........................................................................ 142 Removal.................................................................................... 142 ALTERNATOR INSTALLATION........................................................................ 144 Engine/Alternator Mating................................................................... 144 Alternator Measurement..................................................................... 144 Engine End Play Measurement................................................................ 145 Determining Shim Requirements.............................................................. 146 Installing Alternator On Engine............................................................ 147 ENGINE......................................................................................... 148 Removal.................................................................................... 148 Installation............................................................................... 148 SECTION C5 AIR CLEANERS INDEX.......................................................................... 150 AIR CLEANERS....................................................................................... 152 Service Checks................................................................................. 152 Filter Element Replacement..................................................................... 153 Main Filter Element Cleaning................................................................... 155 Precleaner Section............................................................................. 156 Cleaning Precleaner Tubes...................................................................... 156 Air Intake Troubleshooting..................................................................... 157 SECTION C7 FAN DRIVE CLUTCH INDEX...................................................................... 158 COMPONENTS......................................................................................... 159 Input.......................................................................................... 159 Output......................................................................................... 159 Stationary Components.......................................................................... 160 OPERATIONAL MODES.................................................................................. 161 Fully Engaged.................................................................................. 161 Modulated Variable Speed....................................................................... 161 Fully Released................................................................................. 162 Lubricating and Cooling Oil.................................................................... 163 MAINTENANCE........................................................................................ 164 TROUBLESHOOTING.................................................................................... 165 Preliminary Checks............................................................................. 165 FIELD CHECK DIAGNOSIS.............................................................................. 166 Preliminary Checks - Engine Off................................................................ 166 Check Clutch Release........................................................................... 166 Check Clutch Lock-up........................................................................... 167 Overheating.................................................................................... 167 Thermal Sensor and Solenoid Valve.............................................................. 168 On Truck Test.................................................................................. 168 Off Truck Test................................................................................. 168 FAN CLUTCH DISASSEMBLY INSTRUCTIONS................................................................ 173 REASSEMBLY OF THE FAN CLUTCH....................................................................... 180 INSPECTION OF PARTS................................................................................ 191 REBUILD TOOLS...................................................................................... 195 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX................................................... 196 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX.......................................................... 198 24VDC ELECTRIC SUPPLY SYSTEM....................................................................... 200 ELECTRICAL SYSTEM DESCRIPTION.................................................................. 200 BATTERIES...................................................................................... 200 Maintenance and Service.................................................................... 200 Troubleshooting............................................................................ 200 BATTERY CHARGING ALTERNATOR.................................................................... 202 24VDC ELECTRIC START SYSTEM........................................................................ 202 CRANKING MOTORS................................................................................ 202 Removal.................................................................................... 202 Installation............................................................................... 203 CRANKING MOTOR TROUBLESHOOTING................................................................. 203 Preliminary Inspection..................................................................... 204 No-Load Test............................................................................... 204 Interpreting Results of Tests.............................................................. 204 Disassembly................................................................................ 205 Cleaning and Inspection.................................................................... 205 Armature Servicing......................................................................... 206 Field Coil Checks.......................................................................... 208 Field Coil Removal......................................................................... 208 Solenoid Checks............................................................................ 208 Test....................................................................................... 208 Assembly................................................................................... 210 Pinion Clearance........................................................................... 211 MAGNETIC SWITCH................................................................................ 211 Coil Test.................................................................................. 211 Electric Start System Wiring Diagrams...................................................... 211 ENGINE PRELUB SYSTEM............................................................................... 212 OPERATION...................................................................................... 212 Pressure Switch............................................................................ 212 Suction Line............................................................................... 212 Outlet Line................................................................................ 212 Check Valve................................................................................ 212 Solenoid Timer............................................................................. 212 TROUBLESHOOTING PRELUB STARTER CIRCUIT............................................................. 214 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX.................................................... 218 PASSENGER SEAT BASE COMPARTMENT.................................................................... 220 COMPONENTS......................................................................................... 220 Taillight Resistor Diode Assemblies............................................................ 220 Inclinometer................................................................................... 220 Lubrication System Timer....................................................................... 220 Three Minute Idle Timer Components............................................................. 220 Three Minute Idle Timer........................................................................ 222 Idle Timer Relay............................................................................... 222 Three Minute Idle Contactor.................................................................... 222 Three Minute Idle Circuit Test................................................................. 222 Data Store Button.............................................................................. 222 Komatsu Engine Diagnostic Connector (Centry)................................................... 222 Komatsu Engine Diagnostic Port (CENSE)......................................................... 222 STATEX III Propulsion System Diagnostic Connector.............................................. 222 Modular Mining Port (Optional)................................................................. 222 Alarm Indicating Device (AID) System........................................................... 223 Diode Matrix (Without Sound)................................................................... 223 Diode Matrix (With Sound)...................................................................... 224 Hot Switch Inverter............................................................................ 224 Hot Switch Inverter Card (Slot 4) (Not Used)................................................... 224 Temperature.................................................................................... 224 Oil Level...................................................................................... 224 Temperature and Latch.......................................................................... 224 Coolant Level/Flasher.......................................................................... 225 Lamp Test...................................................................................... 225 BATTERY EQUALIZER BOX.............................................................................. 225 Troubleshooting................................................................................ 225 BODY POSITION SWITCHES............................................................................. 227 Proximity Switch Operation..................................................................... 227 Body-Up Switch Adjustment...................................................................... 228 Hoist Limit Switch Adjustment.................................................................. 228 24-VOLT RELAY AND DIODE BOARDS..................................................................... 230 RELAY BOARDS....................................................................................... 231 Description.................................................................................... 231 SERVICE............................................................................................ 231 To Replace A Relay:............................................................................ 231 To Replace A Circuit Breaker:.................................................................. 231 To Replace A Circuit Panel Card................................................................ 232 Relay Board Components......................................................................... 232 Installing Additional Circuits................................................................. 233 DIODE BOARD 1.................................................................................. 234 Diode Testing.................................................................................. 234 CIRCUIT BREAKERS................................................................................... 236 SECTION D10 BATTERY CHARGING ALTERNATOR INDEX.......................................................... 238 BATTERY CHARGING SYSTEM............................................................................ 242 BATTERY CHARGING SYSTEM........................................................................ 242 ELECTRICAL SYSTEM DESCRIPTION.............................................................. 242 CHARGE VOLT AND AMP VALUES................................................................. 242 BATTERY.................................................................................... 242 Maintenance and Service................................................................ 242 Troubleshooting........................................................................ 243 Undercharging.......................................................................... 243 Overcharging........................................................................... 243 Corrosion.............................................................................. 243 Acid Levels............................................................................ 243 Non-Use or Storage..................................................................... 243 Freezing............................................................................... 244 BATTERY CHARGING ALTERNATOR.................................................................... 245 GENERAL INFORMATION........................................................................ 245 General Description.................................................................... 245 Terminal Identification and Location................................................... 246 Battery Positive (B+).................................................................. 246 Battery Negative (B-).................................................................. 246 DC Output (D+)......................................................................... 246 AC Output (R).......................................................................... 246 Regulator Harness Plug Identification.................................................. 246 Alternator Specifications.............................................................. 246 Performance Curve...................................................................... 246 Battery/Alternator Terminology......................................................... 247 WIRING DIAGRAM............................................................................. 249 DIMENSIONS AND TORQUE VALUES............................................................... 250 PERIODIC MAINTENANCE....................................................................... 251 TESTING........................................................................................ 251 GENERAL INFORMATION........................................................................ 251 Troubleshooting Alternator (On-Truck).................................................. 251 Equipment Required..................................................................... 251 Preliminary Checks..................................................................... 251 Test Set-up............................................................................ 253 Test Procedure......................................................................... 254 REGULATOR TESTING.......................................................................... 255 Regulator Bypass Test (No Output)...................................................... 255 Regulator Bypass Test (Amp Rating)..................................................... 256 BENCH TESTING.............................................................................. 257 Equipment.............................................................................. 257 Identification Record.................................................................. 257 Advanced Troubleshooting............................................................... 257 Bench Test 1: No-Load Test............................................................. 257 Bench Test 2: Full Load Test........................................................... 258 Bench Test 3: Regulator Bypass Test.................................................... 258 STATIC TESTING............................................................................. 259 Equipment.............................................................................. 259 Identification Record.................................................................. 259 Regulator Tester....................................................................... 259 Check For Shorted Power Transistor..................................................... 259 Circuit Tests.......................................................................... 260 FIELD COIL TESTS........................................................................... 261 Field Coil Test 1: Check for Open or Shorted Field Coil................................ 261 Field Coil Test 2: Check For Grounded Field Coil....................................... 261 STATOR TESTS............................................................................... 262 Stator Test 1: Check For Stator-To-Stator Continuity................................... 262 Stator Test 2: Check For Grounded Stators.............................................. 263 THERMAL SWITCH TEST........................................................................ 263 Initial Test........................................................................... 263 Verifying a Faulty Thermal Switch...................................................... 264 TROUBLESHOOTING TIPS....................................................................... 265 ALTERNATOR..................................................................................... 269 ALTERNATOR REPAIR.......................................................................... 269 Removal................................................................................ 269 Installation........................................................................... 271 Special Tools and Lubricants........................................................... 271 Epoxy Adhesive......................................................................... 272 Liquid Threadlockers................................................................... 272 Elastoplastic Silicone Resin........................................................... 272 ALTERNATOR EXPLODED VIEW................................................................... 274 ALTERNATOR DISASSEMBLY..................................................................... 276 Regulator Removal...................................................................... 276 Fan Removal............................................................................ 277 Pulley Removal......................................................................... 278 Anti-Drive End Housing Removal......................................................... 278 Anti-Drive End Rotor Removal........................................................... 280 Drive End Housing Removal.............................................................. 282 Drive End Rotor Removal................................................................ 288 Field Coil Removal..................................................................... 289 Drive End and/or Anti-Drive End Stator Removal......................................... 291 CLEANING AND INSPECTION.................................................................... 293 ALTERNATOR ASSEMBLY........................................................................ 293 Anti-Drive End Stator Installation..................................................... 293 Drive End Stator Installation.......................................................... 295 Field Coil Installation................................................................ 298 Drive End Bearing Installation......................................................... 300 Drive End Rotor Installation........................................................... 302 Rotor and Rotor Shaft Installation..................................................... 302 Drive End Housing Installation......................................................... 303 Anti-Drive End Rotor Installation...................................................... 307 Anti-Drive End Housing Installation.................................................... 308 Regulator Installation................................................................. 311 THERMAL SWITCH............................................................................. 312 Removal................................................................................ 312 Installation........................................................................... 314 SUPPORT STAND.............................................................................. 314 SECTION D35 PAYLOAD METER III INDEX.................................................................... 315 Introduction....................................................................................... 320 Data Summary................................................................................... 320 Data Gathering................................................................................. 320 COMPONENT DESCRIPTION.............................................................................. 321 System Diagram................................................................................. 321 Suspension Pressure Sensors.................................................................... 321 Inclinometer................................................................................... 321 Operator Display............................................................................... 321 Operator Switch................................................................................ 322 Speed Input.................................................................................... 322 Body-Up Switch................................................................................. 322 Brake Lock Switch.............................................................................. 322 Payload Meter.................................................................................. 322 Communications Ports........................................................................... 322 Key Switch Input............................................................................... 323 Payload Meter Power............................................................................ 323 Load Lights.................................................................................... 323 Wiring and Termination......................................................................... 324 TCI Outputs.................................................................................... 324 OPERATOR’S DISPLAY AND SWITCH...................................................................... 325 Reading the Speedometer........................................................................ 325 Reading the Load Display....................................................................... 325 Using the Operator ID.......................................................................... 325 Using the Load and Ton Counter................................................................. 325 Total Ton Counter.............................................................................. 325 Total Load Counter............................................................................. 326 Clearing the Counters.......................................................................... 326 Viewing Live Sensor Data....................................................................... 326 Other Display Messages......................................................................... 326 PAYLOAD OPERATION & CALCULATION.................................................................... 327 Description of Haul Cycle States............................................................... 327 Haul Cycle Description......................................................................... 327 Load Calculation............................................................................... 328 Carry Back..................................................................................... 328 Measurement Accuracy........................................................................... 328 SOURCES FOR PAYLOAD ERROR.......................................................................... 328 Payload Error.................................................................................. 328 Loading Conditions............................................................................. 329 Pressure Sensors............................................................................... 329 Swingloads..................................................................................... 329 Speed and Distance............................................................................. 329 HAUL CYCLE DATA.................................................................................... 329 Haul Cycle Warning Flags....................................................................... 331 Frame Torque Data.............................................................................. 332 Sprung Weight Data............................................................................. 332 Maximum Speed Data............................................................................. 332 Alarm Records.................................................................................. 332 Fault Code Data................................................................................ 333 PC SOFTWARE OVERVIEW............................................................................... 334 System Configuration........................................................................... 334 Installing the PLMIII Software................................................................. 334 DOWNLOADING DATA................................................................................... 335 PLM III SYSTEM CONFIGURATION....................................................................... 336 Starting Communications........................................................................ 336 Displayed Payload Units........................................................................ 336 Time Units..................................................................................... 336 Connection Menu................................................................................ 336 Connecting to the Payload Meter................................................................ 337 Configure the Payload Meter.................................................................... 337 Setting the Date and Time...................................................................... 337 Setting the Truck Type......................................................................... 338 Setting the Gauge Display Units................................................................ 338 Setting the Frame Serial Number................................................................ 338 Setting the Truck Number....................................................................... 338 Setting the Komatsu Distributor................................................................ 338 Setting the Komatsu Customer................................................................... 338 Setting the Overload Speed Limit Function...................................................... 339 Clean Truck Tare............................................................................... 340 Inclinometer Calibration....................................................................... 340 DATA ANALYSIS...................................................................................... 341 Creating a Query............................................................................... 341 Sorting on Truck Unit Number................................................................... 341 Sorting on Truck Type.......................................................................... 341 Sorting on Date Range.......................................................................... 342 Sorting on Time Range.......................................................................... 342 Payload Detail Screen.......................................................................... 343 Creating Reports............................................................................... 343 Summary - one page report...................................................................... 344 Detailed - multi-page report................................................................... 344 Creating Graphs................................................................................ 345 Exporting Data................................................................................. 345 CSV Export..................................................................................... 345 Compressed..................................................................................... 346 Importing Data................................................................................. 347 Deleting Haul Cycle Records.................................................................... 347 Viewing Alarms................................................................................. 348 Deleting Alarm Records......................................................................... 348 TROUBLESHOOTING SECTION............................................................................ 349 TROUBLESHOOTING................................................................................ 349 Viewing Active Alarms...................................................................... 349 Real-Time Data Display..................................................................... 349 Testing the Payload Lights................................................................. 349 Creating Log Files of Inputs............................................................... 350 Daily Inspections.......................................................................... 350 Periodic Maintenance....................................................................... 350 Abnormal Displays at Power-Up.............................................................. 351 No Payload Display When Key Switch is Turned ON............................................ 352 No Display on Speedometer.................................................................. 353 No Display on Operator Display............................................................. 353 No Communications With PC.................................................................. 354 Load Lights Don’t Light During Loading..................................................... 355 Load Lights Remain ON...................................................................... 356 Load Lights Remain ON During Dumping....................................................... 356 Display Doesn't Clear When The Load Is Dumped.............................................. 356 Calibration Problems....................................................................... 357 Alarm 1 - Left Front Pressure High......................................................... 358 Alarm 2 - Left Front Pressure Low.......................................................... 358 Troubleshoot Wiring to Left Front Suspension............................................... 358 Alarm 3 - Right Front Pressure High........................................................ 359 Alarm 4 - Right Front Pressure Low......................................................... 359 Troubleshoot Wiring to Right Front Suspension.............................................. 359 Alarm 5 -Left Rear Pressure High........................................................... 360 Alarm 6 - Left Rear Pressure Low........................................................... 360 Troubleshoot Wiring to Left Rear Suspension................................................ 360 Alarm 7 - Right Rear Pressure High......................................................... 361 Alarm 8 - Right Rear Pressure Low.......................................................... 361 Troubleshoot Wiring to Right Rear Suspension............................................... 361 Alarm 9 - Inclinometer High................................................................ 362 Alarm 10 - Inclinometer Low................................................................ 362 Troubleshoot Inclinometer Wiring........................................................... 362 Alarm 13 - Body Up Input Failure........................................................... 363 Alarm 16 - Memory Write Failure............................................................ 364 Alarm 17 - Memory Read Failure............................................................. 364 Alarm 18................................................................................... 364 Alarm 19................................................................................... 364 Alarm 22................................................................................... 364 Operator Switch Doesn't Work............................................................... 365 Alarm 26 - User Switch Fault - SELECT...................................................... 365 Alarm 27 - User Switch Fault - SET......................................................... 365 Connector Map.............................................................................. 366 Connectors................................................................................. 367 General Description........................................................................ 368 Tools Required............................................................................. 368 Checkout Procedure......................................................................... 368 PLMIII CHECKOUT PROCEDURE CONFIRMATION......................................................... 372 Flashburn Programming...................................................................... 372 Confirmation Checklist..................................................................... 374 SECTION E ELECTRICAL PROPULSION INDEX...................................................................... 375 SECTION E2 ELECTRICAL PROPULSION COMPONENTS........................................................... 377 ELECTRICAL PROPULSION COMPONENTS................................................................... 381 GENERAL SYSTEM DESCRIPTION..................................................................... 381 CONTROL SYSTEM................................................................................. 381 System Operation............................................................................... 382 FL275 Panel.................................................................................... 383 CARD REPLACEMENT............................................................................... 384 Removal........................................................................................ 384 Installation................................................................................... 384 Card Repair.................................................................................... 384 Panel Wiring................................................................................... 384 COMPUTER DESCRIPTION........................................................................... 385 Microprocessor................................................................................. 385 Download Capability............................................................................ 385 SOFTWARE....................................................................................... 385 Base Monitor Program........................................................................... 385 Runtime Monitor Program - OBJ Running Code..................................................... 385 Configuration Software - CFG................................................................... 386 PTU - Portable Test Unit Code.................................................................. 386 System Regulation.............................................................................. 386 Propulsion..................................................................................... 387 Retarding...................................................................................... 387 TWO-DIGIT DISPLAY PANEL........................................................................ 388 The Coded Number............................................................................... 388 Events......................................................................................... 388 Frames......................................................................................... 389 Windows........................................................................................ 389 System Categories.............................................................................. 389 Limits On Resetting Faults..................................................................... 389 NA Faults...................................................................................... 390 Event Sequence................................................................................. 390 Resetting Events............................................................................... 390 Event Descriptions............................................................................. 390 Subcode Descriptions........................................................................... 390 2-DIGIT DISPLAY PANEL SUBCODES................................................................. 398 PORTABLE TEST UNIT (PTU)....................................................................... 401 DESCRIPTION.................................................................................... 401 Operational Hints.............................................................................. 401 SOFTWARE INSTALLATION PREPARATION.............................................................. 402 HARD DISK SPACE REQUIREMENTS................................................................... 402 SOFTWARE INSTALLATION ON PTU................................................................... 402 PTU/Truck Communication Problems............................................................... 403 THE MAIN MENU.................................................................................. 404 Quit Menu...................................................................................... 404 PTU Talk To Truck.............................................................................. 404 View PTU Saved Files........................................................................... 404 List Stat Data Files........................................................................... 404 Truck Setup (CFG).............................................................................. 404 Select Truck Setup............................................................................. 404 Update CFG Version............................................................................. 404 Change PTU Password............................................................................ 404 CONFIGURATION (CFG) FILE CONVERSION............................................................ 406 Conversion Procedure........................................................................... 406 Convert Old CFG files for New software......................................................... 407 STATEX CONFIGURATION FILES..................................................................... 410 0) Source Directory: . . ...................................................................... 410 1) Select A Truck Configuration . . ........................................................... 411 2) View Truck Configuration: Data Curves . . .................................................. 412 3) Change/View Serial and Model Numbers . . ................................................... 413 4) View Options . . ........................................................................... 413 5) Change/View Truck Specifics . . ............................................................ 415 6) Change/View Overspeeds . . ................................................................. 417 7) Save a Truck Configuration, filename: . . .................................................. 418 8) Save Directory: . . ........................................................................ 419 CHANGE PTU PASSWORD............................................................................ 420 PROGRAMMING THE TRUCK.......................................................................... 421 Connect PTU to the Truck....................................................................... 421 Select Configuration File...................................................................... 421 Activate The PTU Mode.......................................................................... 421 Check Object Code Version...................................................................... 422 Download Configuration Files................................................................... 423 Date And Time.................................................................................. 424 Event Data..................................................................................... 425 Statistical Data............................................................................... 427 View Counters.................................................................................. 427 View Profiles.................................................................................. 427 Upload Statistical Data To A File.............................................................. 427 Statistical Data Codes - Counters.............................................................. 428 STATISTICAL DATA CODES - COUNTERS.............................................................. 429 STATISTICAL DATA CODES - PROFILES.............................................................. 434 TRUCK SPECIFIC INFORMATION..................................................................... 438 Temporary Truck Settings....................................................................... 439 MISCELLANEOUS FEATURES......................................................................... 440 Saving Data.................................................................................... 440 PTU Abbreviations.............................................................................. 441 Other Menu Selections.......................................................................... 441 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS................................................. 442 ALTERNATOR..................................................................................... 442 ELECTRIC WHEEL MOTORS.......................................................................... 442 RETARDING GRIDS................................................................................ 442 ELECTRONIC ACCELERATOR AND RETARD PEDALS....................................................... 442 Removal........................................................................................ 442 Installation................................................................................... 442 Disassembly.................................................................................... 443 Reassembly..................................................................................... 443 COOLING BLOWER WARNING SYSTEM.................................................................. 443 Operation...................................................................................... 443 Test........................................................................................... 443 Removal........................................................................................ 444 Installation................................................................................... 444 ELECTRICAL CONTROL CABINET..................................................................... 445 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS......................................... 450 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III............................................. 451 SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE............................................ 453 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.................................................... 457 GENERAL INFORMATION............................................................................ 457 COMMUNICATIONS PORT CHECK...................................................................... 458 PTU Hookup..................................................................................... 458 4.0 SEQUENCE TESTS - (ENGINE NOT ON)........................................................... 459 Preparation and Setup.......................................................................... 459 CONTROL SYSTEM SELF-TEST....................................................................... 460 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT....................................................... 460 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT......................................................... 461 PTU Setup...................................................................................... 461 4.3 REVERSER AND PROPULSION CONTACTORS CHECK................................................... 462 4.4 NOT USED................................................................................... 463 4.5 RETARD CONTACTORS OPERATION CHECK.......................................................... 463 4.6 GROUND FAULT SENSING CHECK................................................................. 463 4.7 GROUND FAULT IN RETARD OPERATION CHECK..................................................... 464 4.8 OVERRIDE OPERATION CHECK................................................................... 464 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK.......................................................... 465 4.10 OVERSPEED RETARD OPERATION CHECK.......................................................... 465 4.11 HOIST INTERLOCK OPERATION CHECK........................................................... 466 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.................................................. 466 Return to Main Menu............................................................................ 466 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL....................................... 467 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.............................................. 467 5.2 DIGITAL INPUT CHECKS....................................................................... 468 5.3 DIGITAL OUTPUT CHECKS...................................................................... 469 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL............................................... 473 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU................................................... 473 6.2 ANALOG INPUT CHECKS........................................................................ 474 6.3 FREQUENCY INPUT CHECKS..................................................................... 478 Return to Main Menu............................................................................ 479 7.0 SPEED EVENT CHECKS......................................................................... 479 Preparation and Setup.......................................................................... 479 Setup PTU...................................................................................... 479 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK.................................... 480 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK......................... 480 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK........................ 480 7.4 OTHER SPEED EVENTS CHECKS.................................................................. 480 Return to Main Menu............................................................................ 480 8.0 RETARD SPEED CONTROL SYSTEM CHECK.......................................................... 481 Preparation and Setup.......................................................................... 481 Setup PTU...................................................................................... 481 8.1 OVERSPEED PICKUP AND DROPOUT CHECK......................................................... 481 8.2 RETARD POT MAXIMUM SETTING CHECK........................................................... 481 8.3 RETARD POT MINIMUM SETTING CHECK........................................................... 481 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL......................................... 482 Return to Main Menu............................................................................ 482 9.0 LOAD TEST USING TRUCK RETARD GRIDS......................................................... 482 Setup and Preparation.......................................................................... 482 PTU Setup...................................................................................... 482 9.1 LOAD TEST.................................................................................. 483 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING.................................................... 483 Setup PTU...................................................................................... 483 10.1 RETARD CHECK.............................................................................. 484 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT............................................... 485 11.1 BRAKE SYSTEM INTERLOCKS CHECK............................................................. 485 Preparation.................................................................................... 485 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT.................................................... 485 11.3 SYNC TRANSFORMER CHECKOUT................................................................. 486 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT................................................ 486 11.5 BATTERY BOOST ADJUSTMENT.................................................................. 486 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST............................................... 486 11.7 MOTOR ROTATION TEST....................................................................... 487 11.8 GROUND FAULT CHECKS....................................................................... 487 12.0 MISCELLANEOUS CHARTS...................................................................... 488 12.1 WHEEL MOTOR GEAR RATIOS................................................................... 488 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS............................................................ 489 12.3 ENGINE OPTIONS............................................................................ 490 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX............................................................ 491 SECTION G2 TIRES AND RIMS INDEX........................................................................ 493 GENERAL INFORMATION................................................................................ 495 TIRES.............................................................................................. 495 Handling Tires................................................................................. 495 Tire Maintenance............................................................................... 496 Storing Tires After Removal.................................................................... 496 FRONT TIRES AND RIMS............................................................................... 497 Removal........................................................................................ 497 Installation................................................................................... 498 REAR TIRES AND RIMS................................................................................ 499 Removal........................................................................................ 499 Installation................................................................................... 500 RIM............................................................................................ 501 Tire Removal................................................................................... 501 RIM AND TIRE PREPARATION........................................................................... 502 LUBRICANTS......................................................................................... 502 TIRE INSTALLATION.................................................................................. 503 SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX........................................................... 505 FRONT WHEEL HUB AND SPINDLE........................................................................ 507 WHEEL HUB AND SPINDLE ASSEMBLY................................................................. 507 Removal.................................................................................... 507 Installation............................................................................... 509 Disassembly................................................................................ 510 Cleaning and Inspection.................................................................... 511 Assembly................................................................................... 511 Wheel Bearing Adjustment (Spindle Vertical)................................................ 514 Wheel Bearing Adjustment (Tire Mounted).................................................... 515 Spindle Removal Procedure (Optional) (off of the truck).................................... 518 STEERING CYLINDERS AND TIE ROD................................................................. 520 Spherical Bearing Wear Limits.............................................................. 520 Removal.................................................................................... 521 Installation............................................................................... 523 Bearing Replacement........................................................................ 523 TOE-IN ADJUSTMENT.............................................................................. 524 SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX......................................................... 525 PIVOT PIN.......................................................................................... 527 Removal........................................................................................ 527 Installation................................................................................... 528 PIVOT EYE BEARING.................................................................................. 528 Disassembly.................................................................................... 528 Assembly....................................................................................... 529 PIVOT EYE REPAIR................................................................................... 529 Removal........................................................................................ 529 Disassembly.................................................................................... 529 Bushing (New).................................................................................. 529 Pivot Eye Bore (New)........................................................................... 529 Assembly....................................................................................... 529 Installation................................................................................... 530 ANTI-SWAY BAR...................................................................................... 530 Removal........................................................................................ 530 Installation................................................................................... 530 Disassembly.................................................................................... 531 Cleaning and Inspection........................................................................ 531 Assembly....................................................................................... 531 SECTION G5 REAR AXLE HOUSING.......................................................................... 533 REAR AXLE HOUSING.................................................................................. 535 REAR AXLE HOUSING.............................................................................. 535 Removal.................................................................................... 535 Installation............................................................................... 535 WHEEL MOTOR.................................................................................... 536 Removal.................................................................................... 536 Cleaning and Inspection.................................................................... 536 Installation............................................................................... 537 WHEEL MOTOR GEAR OIL........................................................................... 540 Change/Filter The Gear case Oil............................................................ 540 Oil........................................................................................ 540 Remove And Clean Magnetic Plugs............................................................ 540 Flushing The Gearbox....................................................................... 540 Check Gear Case Oil Level.................................................................. 540 SECTION H SUSPENSIONS INDEX................................................................................ 541 SECTION H2 FRONT SUSPENSION INDEX...................................................................... 543 Removal............................................................................................ 545 Installation....................................................................................... 547 Angle Advance Tightening Procedure................................................................. 548 Disassembly........................................................................................ 549 Cleaning and Inspection............................................................................ 550 Assembly (Bearing Only)............................................................................ 550 Suspension Assembly (Complete)..................................................................... 550 SUSPENSION PRESSURE TEST........................................................................... 552 SECTION H3 REAR SUSPENSIONS INDEX...................................................................... 555 Removal............................................................................................ 558 Installation....................................................................................... 560 Disassembly........................................................................................ 560 Cleaning and Inspection............................................................................ 561 Assembly........................................................................................... 561 SUSPENSION PRESSURE TEST........................................................................... 563 SECTION H4 OILING AND CHARGING PROCEDURES INDEX........................................................ 565 GENERAL............................................................................................ 567 EQUIPMENT LIST..................................................................................... 567 Hydrair® Charging Kit.......................................................................... 567 Installation of Charging Kit................................................................... 567 Removal of Charging Kit........................................................................ 568 Support Blocks For Oiling and Charging Dimensions.............................................. 568 FRONT SUSPENSION................................................................................... 569 Front Suspension Oiling........................................................................ 569 Front Suspension Nitrogen Charging............................................................. 570 REAR SUSPENSION.................................................................................... 572 Rear Suspension Oiling......................................................................... 572 Rear Suspension Nitrogen Charging.............................................................. 574 SECTION J BRAKE CIRCUIT INDEX.............................................................................. 577 SECTION J2 BRAKE CIRCUIT INDEX......................................................................... 579 GENERAL DESCRIPTION................................................................................ 581 SERVICE BRAKE CIRCUIT.............................................................................. 581 SECONDARY BRAKING AND AUTOMATIC APPLY.............................................................. 583 PARKING BRAKE CIRCUIT.............................................................................. 583 Normal Operation (key switch on, engine on).................................................... 583 BRAKE LOCK CIRCUIT................................................................................. 584 WARNING CIRCUIT.................................................................................... 584 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX....................................................... 587 BRAKE CIRCUIT COMPONENT SERVICE.................................................................... 589 BRAKE VALVE.................................................................................... 589 Rebuild Criteria........................................................................... 589 Removal.................................................................................... 589 Installation............................................................................... 591 Disassembly................................................................................ 593 Cleaning and Inspection.................................................................... 595 ASSEMBLY....................................................................................... 595 Actuator Base Threaded Inserts............................................................. 595 Boot and Cap............................................................................... 595 Valve Body Seal Installation............................................................... 596 Regulator Sleeve O-Ring Installation....................................................... 597 Actuator Plunger O-Ring Installation....................................................... 597 Assembly of Valve.......................................................................... 597 DIFFERENTIAL PRESSURE SWITCH................................................................... 598 Disassembly................................................................................ 599 Cleaning and Inspection.................................................................... 599 Assembly................................................................................... 599 VALVE BENCH TEST AND ADJUSTMENT................................................................ 599 Test Set Up Procedure...................................................................... 601 Brake Valve Output Pressure Adjustment..................................................... 601 Differential Pressure Switch Test.......................................................... 602 Final Test and Adjustment.................................................................. 602 Installation Of Brake Pedal Actuator Assembly to Brake Valve............................... 603 HYDRAULIC BRAKE ACCUMULATORS................................................................... 605 Brake Accumulator Bleed-Down Procedure..................................................... 605 Removal.................................................................................... 605 Installation............................................................................... 607 Disassembly................................................................................ 607 Cleaning and Inspection.................................................................... 609 Assembly................................................................................... 609 Leak Testing............................................................................... 612 BRAKE ACCUMULATOR CHARGING..................................................................... 613 Temperature During Precharge............................................................... 615 ACCUMULATOR STORAGE............................................................................ 615 Installation............................................................................... 616 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX..................................................... 617 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................................. 619 EQUIPMENT REQUIRED............................................................................. 622 INITIAL SYSTEM SET-UP.......................................................................... 623 Parking Brake.............................................................................. 623 Service Brakes............................................................................. 624 Brake Lock/Secondary....................................................................... 624 Low Brake Pressure and Auto Apply.......................................................... 625 Reapplications............................................................................. 625 Differential Pressure Switch............................................................... 625 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...................................................... 627 The Brakes are Locked, Service, and/or Parking................................................. 627 Both Brake Circuits are Dragging............................................................... 627 One Brake Circuit is Dragging.................................................................. 627 Brakes are Not Going to Full Pressure.......................................................... 627 A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off......................... 627 Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released.... 628 Differential Pressure Warning Circuit is Not Operating......................................... 628 A Low Brake Pressure Warning Occurs When Brakes are Applied.................................... 628 Low Pressure Warning Circuit Not Operating Properly............................................ 628 Low Pressure Warning is On Even Though System Pressure is Correct.............................. 629 Low Pressure Warning Comes On and Pressure is Low.............................................. 629 A Squeal is Heard When Controller is Operated.................................................. 629 Output Pressure At Controller is Correct but Brakes are Not Applying........................... 629 Brake Pressures Drift Excessively While Pedal is Held Steady................................... 629 Oil is Leaking Around the Pedal Base........................................................... 629 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM....................... 629 CHECK-OUT PROCEDURE................................................................................ 630 HYDRAULIC BRAKE SYSTEM DATA SHEET.................................................................. 630 SECTION J5 FRONT DISC BRAKES INDEX..................................................................... 633 BRAKE CALIPER...................................................................................... 635 Removal........................................................................................ 635 Installation................................................................................... 636 Disassembly.................................................................................... 637 Cleaning and Inspection........................................................................ 637 Assembly....................................................................................... 639 BRAKE LINING....................................................................................... 639 Replacement.................................................................................... 639 FRONT SERVICE BRAKE BURNISHING..................................................................... 641 BRAKE BLEEDING PROCEDURE....................................................................... 642 REAR DISC BRAKES................................................................................... 645 REAR BRAKES.................................................................................... 645 CALIPER, DISC, AND PARKING BRAKE............................................................... 645 Removal.................................................................................... 645 Installation............................................................................... 646 CALIPER PISTON................................................................................. 648 Piston Assembly Removal.................................................................... 648 Inspection................................................................................. 648 Piston Assembly Installation............................................................... 649 FUNCTIONAL TEST OF PISTON ASSEMBLY............................................................. 650 Return Spring Force........................................................................ 650 Built-In Clearance......................................................................... 650 Grip Force................................................................................. 652 Grip Force Measurement..................................................................... 653 Spring Force Measurement................................................................... 655 Disassembly of Piston Assembly............................................................. 656 Assembly of Piston Assembly................................................................ 657 BENCH TEST..................................................................................... 657 BRAKE LINING................................................................................... 658 Replacement................................................................................ 658 SERVICE BRAKE BURNISHING........................................................................... 661 SAFETY PRECAUTIONS............................................................................. 661 Rear Brake Burnishing...................................................................... 662 BRAKE BLEEDING PROCEDURE....................................................................... 663 Spring Force Measurement................................................................... 664 SECTION J6 REAR BRAKES INDEX........................................................................... 643 SECTION J7 PARKING BRAKE INDEX......................................................................... 665 GENERAL INFORMATION................................................................................ 667 PARKING BRAKE CALIPER.............................................................................. 667 Lining Thickness Inspection.................................................................... 667 Removal........................................................................................ 668 Installation................................................................................... 668 Parking Brake Adjustment....................................................................... 669 Parking Brake Caliper Disassembly.............................................................. 670 Cleaning and Inspection........................................................................ 671 Parking Brake Caliper Assembly................................................................. 672 PARKING BRAKE LINING REPLACEMENT................................................................... 672 PARKING BRAKE BURNISH PROCEDURE.................................................................... 672 Lining Conditioning............................................................................ 672 BRAKE BLEEDING PROCEDURE........................................................................... 673 SECTION L HYDRAULIC SYSTEM INDEX........................................................................... 675 SECTION L2 HYDRAULIC SYSTEM OVERVIEW.................................................................. 677 HYDRAULIC SYSTEM OVERVIEW.......................................................................... 678 Hoist Circuit Operation........................................................................ 678 Steering, Brake and Pantograph Circuit Operation............................................... 678 Axle Blower System Operation................................................................... 678 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR.......................................................... 681 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................................. 683 HOIST PUMP..................................................................................... 683 Removal.................................................................................... 683 Installation............................................................................... 685 Disassembly................................................................................ 685 Inspection................................................................................. 688 Assembly................................................................................... 689 PISTON PUMP................................................................................ 694 Removal................................................................................ 694 Installation........................................................................... 695 Disassembly............................................................................ 697 Inspection of Parts.................................................................... 703 Assembly............................................................................... 705 AXLE BLOWER HYDRAULIC MOTOR........................................................................ 710 Removal........................................................................................ 710 Installation................................................................................... 710 Rear Axle Blower Housing....................................................................... 710 Disassembly................................................................................ 710 Assembly................................................................................... 711 Disassembly................................................................................ 713 Inspection................................................................................. 715 Assembly................................................................................... 716 Trouble Shooting........................................................................... 717 Hand Wheel Control............................................................................. 718 Disassembly................................................................................ 718 Assembly................................................................................... 718 HYDRAULIC TANK................................................................................. 720 Filling Instructions....................................................................... 720 Removal.................................................................................... 721 Installation............................................................................... 721 HYDRAULIC TANK STRAINER AND DIFFUSER........................................................... 722 Removal.................................................................................... 722 Inspect and Clean.......................................................................... 723 Installation............................................................................... 723 SECTION L4 STEERING CIRCUIT INDEX...................................................................... 725 STEERING CIRCUIT OPERATION......................................................................... 727 COMPONENT DESCRIPTION.............................................................................. 728 Steering Control Valve......................................................................... 728 Unloader Valve................................................................................. 729 Bleed-Down Manifold Valve...................................................................... 729 Flow Amplifier................................................................................. 734 FLOW AMPLIFIER SYSTEM OPERATION.................................................................... 735 No Steer....................................................................................... 735 Steering Left.................................................................................. 737 Steering Right................................................................................. 739 No Steer, External Shock Load.................................................................. 741 Steering Pump.................................................................................. 743 High Pressure Filter........................................................................... 743 Accumulators................................................................................... 743 Low Precharge Warning Switch................................................................... 743 SECTION L5 STEERING CONTROL VALVE INDEX................................................................ 745 Removal............................................................................................ 747 Installation....................................................................................... 748 STEERING CONTROL VALVE REBUILD..................................................................... 749 Disassembly.................................................................................... 749 Cleaning and Inspection........................................................................ 750 Assembly....................................................................................... 750 BRAKE / STEERING PUMP.............................................................................. 754 Removal........................................................................................ 754 Installation................................................................................... 756 Disassembly.................................................................................... 757 Inspection of Parts............................................................................ 757 Assembly....................................................................................... 759 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX..................................................... 761 STEERING CIRCUIT COMPONENT REPAIR.................................................................. 763 BLEED-DOWN MANIFOLD............................................................................ 763 Removal.................................................................................... 763 Installation............................................................................... 763 ACCUMULATOR.................................................................................... 764 Removal.................................................................................... 764 Installation............................................................................... 765 Disassembly................................................................................ 766 Cleaning and Inspection.................................................................... 766 Assembly................................................................................... 767 Leak Testing............................................................................... 768 STEERING ACCUMULATOR CHARGING.................................................................. 769 Temperature During Precharge............................................................... 772 ACCUMULATOR STORAGE............................................................................ 773 Installation............................................................................... 773 FLOW AMPLIFIER................................................................................. 774 Removal.................................................................................... 774 Installation............................................................................... 774 Disassembly................................................................................ 775 Assembly................................................................................... 778 STEERING CYLINDERS............................................................................. 779 Disassembly................................................................................ 779 Piston Seal and Bearing Installation....................................................... 779 Cylinder Assembly.......................................................................... 779 Test....................................................................................... 779 TROUBLESHOOTING CHART.............................................................................. 782 SECTION L7 HOIST CIRCUIT INDEX......................................................................... 787 HOIST CIRCUIT OPERATION............................................................................ 789 COMPONENT DESCRIPTION.............................................................................. 790 Hydraulic Tank................................................................................. 790 Hydraulic Pump................................................................................. 790 High Pressure Filter........................................................................... 790 Hoist Valve.................................................................................... 790 Hoist Pilot Valve.............................................................................. 791 Bleed-Down Manifold............................................................................ 792 Counterbalance Manifold........................................................................ 792 Hoist-Up Limit Solenoid........................................................................ 792 Pilot Operated Check Valve..................................................................... 792 HOIST VALVE OPERATION.............................................................................. 794 Float Operation................................................................................ 794 Power Up Operation (Figure 7-6)................................................................ 796 Hold Operation (Figure 7-7).................................................................... 798 Power Down Operation (Figure 7-8).............................................................. 800 Float Operation (Figure 7-9)................................................................... 802 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX........................................................ 805 HOIST VALVE........................................................................................ 807 Removal........................................................................................ 807 Installation................................................................................... 807 O-Ring Replacement............................................................................. 809 INLET SECTION...................................................................................... 810 Disassembly.................................................................................... 810 Cleaning and Inspection........................................................................ 811 Assembly....................................................................................... 811 REAR SPOOL SECTION (WORK PORTS).................................................................... 812 Disassembly.................................................................................... 812 Cleaning and Inspection........................................................................ 814 Assembly....................................................................................... 814 HOIST PILOT VALVE.................................................................................. 816 Removal........................................................................................ 816 Installation................................................................................... 816 Disassembly.................................................................................... 817 Cleaning and Inspection........................................................................ 818 Assembly....................................................................................... 818 HOIST UP LIMIT SOLENOID VALVE...................................................................... 819 HOIST CYLINDERS.................................................................................... 820 Removal........................................................................................ 820 Installation................................................................................... 821 Disassembly.................................................................................... 823 Cleaning and Inspection........................................................................ 824 SS1143 Tightening Tool - Assembly Drawing...................................................... 825 ASSEMBLY OF QUILL AND CYLINDER..................................................................... 825 Quill Installation............................................................................. 825 Installation Of Check Balls And Plugs In Quill................................................. 826 Assembly of Cylinder........................................................................... 828 Pressure Testing............................................................................... 829 COUNTERBALANCE MANIFOLD............................................................................ 829 SECTION L9 HIGH PRESSURE FILTERS INDEX................................................................. 831 HOIST CIRCUIT FILTER............................................................................... 833 Filter Element Replacement..................................................................... 833 Removal........................................................................................ 834 Installation................................................................................... 834 Indicator Switch............................................................................... 834 STEERING CIRCUIT FILTER............................................................................ 835 Filter Element Replacement..................................................................... 835 Removal........................................................................................ 836 Installation................................................................................... 836 Indicator Switch............................................................................... 836 INDICATOR SWITCH................................................................................... 836 Test Procedure................................................................................. 836 SECTION L10 HYDRAULIC CHECK-OUT PROCEDURE INDEX........................................................ 839 INITIAL START UP AND FLUSHING...................................................................... 841 COMPONENT CHECKOUT AND ADJUSTMENT.................................................................. 843 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE...................................... 845 Counterbalance Valve Adjustment................................................................ 847 Manifold Assembly.............................................................................. 847 OIL CLEANLINESS CHECK.............................................................................. 847 Oil Sampling Location On Truck................................................................. 847 Oil Sampling Process and Cleanliness Criteria.................................................. 848 DISABLED TRUCK DUMPING PROCEDURE................................................................... 848 Hookup......................................................................................... 848 Raising the Body............................................................................... 848 Lowering the Body.............................................................................. 849 TROUBLESHOOTING CHART.............................................................................. 850 Hoist Pump..................................................................................... 850 Steering Circuit............................................................................... 852 Brake/Steering Pump............................................................................ 854 Flow Amplifier - Refer to Figure 10-9.......................................................... 856 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 RADIATOR SHUTTERS.................................................................................. 895 OPERATION...................................................................................... 895 Hydraulic Circuit.......................................................................... 895 Electrical Circuit:........................................................................ 896 MAINTENANCE AND REPAIR......................................................................... 896 TROUBLESHOOTING................................................................................ 897 Hydraulic Troubleshooting.................................................................. 900 Electrical Troubleshooting................................................................. 902 SECTION M19 RADIATOR SHUTTERS INDEX.................................................................... 893 SECTION N OPERATOR'S CAB INDEX............................................................................. 903 SECTION N2 TRUCK CAB INDEX............................................................................. 905 TRUCK CAB.......................................................................................... 908 TRUCK CAB...................................................................................... 908 Description................................................................................ 908 Removal.................................................................................... 909 Installation............................................................................... 911 CAB DOOR....................................................................................... 911 Removal.................................................................................... 911 Installation............................................................................... 912 Door Adjustment............................................................................ 912 Door Jam Bolt Adjustment................................................................... 912 Door Handle Plunger Adjustment............................................................. 914 Replace Door Glass......................................................................... 915 Replace Door Window Regulator.............................................................. 919 Replace Door Handle or Latch Assembly...................................................... 919 Door and Door Hinge Seal Replacement....................................................... 920 Door Opening Seal Removal.................................................................. 920 Installation............................................................................... 920 GLASS REPLACEMENT.............................................................................. 921 Adhesive-Bonded Windows.................................................................... 921 Recommended Tools/Supplies................................................................. 921 Replacement Procedure...................................................................... 921 Windshield and Rear Glass.................................................................. 922 Removal.................................................................................... 922 Installation............................................................................... 923 Removal and Installation of Operator Seat...................................................... 924 Inspection................................................................................. 924 Removal.................................................................................... 924 Installation............................................................................... 924 Removal and Installation of Passenger Seat..................................................... 925 Removal.................................................................................... 925 Installation............................................................................... 925 SECTION N3 CAB COMPONENTS INDEX........................................................................ 926 WINDSHIELD WIPERS.................................................................................. 928 WIPER MOTOR REPLACEMENT........................................................................ 928 Removal.................................................................................... 928 Installation............................................................................... 928 WIPER ARM REPLACEMENT.......................................................................... 928 Removal.................................................................................... 928 Installation............................................................................... 929 WIPER LINKAGE REPLACEMENT...................................................................... 929 Removal.................................................................................... 929 Installation............................................................................... 930 WINDSHIELD WASHER.............................................................................. 930 Operation.................................................................................. 930 Service.................................................................................... 930 SEAT BELT...................................................................................... 931 Removal.................................................................................... 931 Installation............................................................................... 931 SECTION N4 OPERATOR COMFORT INDEX...................................................................... 934 HEATER/AIR CONDITIONER............................................................................. 938 CONTROLS....................................................................................... 938 Operation.................................................................................. 938 Heater/Air Conditioner Vents............................................................... 938 Defroster Vent Control Switch.............................................................. 938 Heat Control Switch........................................................................ 938 Temperature Control Knob................................................................... 938 Fan Control Knob........................................................................... 938 Heater/Air Conditioner Selector Switch..................................................... 938 COMPONENTS..................................................................................... 939 Circuit Breakers........................................................................... 939 Relays..................................................................................... 939 Heater Core................................................................................ 939 Fan Motor and Speed Control................................................................ 940 Test....................................................................................... 940 Actuators.................................................................................. 940 Test....................................................................................... 940 Cab Air Filter............................................................................. 941 AIR CONDITIONING SYSTEM............................................................................ 943 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES...................................................... 944 PRINCIPLES OF REFRIGERATION.................................................................... 944 Air Conditioning........................................................................... 944 Refrigeration - The Act of Cooling......................................................... 945 The Refrigeration Cycle.................................................................... 945 AIR CONDITIONER SYSTEM COMPONENTS.............................................................. 946 Compressor (Refrigerant Pump).............................................................. 946 Service Valves............................................................................. 946 Receiver-Drier............................................................................. 946 Condenser.................................................................................. 946 Expansion Block Valve...................................................................... 947 Accumulator................................................................................ 947 Evaporator................................................................................. 948 ELECTRICAL CIRCUIT............................................................................. 948 Thermostat................................................................................. 948 Compressor Clutch.......................................................................... 949 Trinary™ Switch............................................................................ 949 SYSTEM SERVICING............................................................................... 951 SERVICE TOOLS AND EQUIPMENT.................................................................... 952 Recovery/Recycle Station................................................................... 952 Leak Detector.............................................................................. 953 Service Valves............................................................................. 953 Vacuum Pump................................................................................ 953 Manifold Gauge Set......................................................................... 954 Low Side Gauge............................................................................. 954 High Side Gauge............................................................................ 954 Installing Manifold Gauge Set.............................................................. 955 Purging Air From Service Hoses............................................................. 955 SYSTEM PERFORMANCE TEST........................................................................ 956 SYSTEM OIL..................................................................................... 957 Handling and Reusing RPAG Oil.............................................................. 957 Oil Quantity............................................................................... 957 Checking System Oil........................................................................ 957 REFRIGERANT.................................................................................... 958 Recycled Refrigerant....................................................................... 958 Reclaimed Refrigerant...................................................................... 958 Refrigerant Quantity....................................................................... 959 R-134a Refrigerant Containers.............................................................. 959 SYSTEM LEAK TESTING............................................................................ 959 Electronic Leak Detector................................................................... 960 Tracer Dyes................................................................................ 960 Soap and Water............................................................................. 960 RECOVERING AND RECYCLING THE REFRIGERANT....................................................... 960 Performing the Recovery Cycle.............................................................. 960 Performing the Recycling Procedure......................................................... 961 Evacuating and Charging the A/C System..................................................... 961 SYSTEM REPAIR.................................................................................. 961 System Flushing............................................................................ 962 COMPONENT REPLACEMENT.......................................................................... 962 Hoses and Fittings......................................................................... 962 Lines...................................................................................... 962 Expansion Valve............................................................................ 963 Receiver-Drier............................................................................. 963 Thermostat................................................................................. 963 Compressor................................................................................. 963 Accumulator................................................................................ 964 Clutch..................................................................................... 964 Servicing the Compressor Clutch............................................................ 965 Pulley Removal............................................................................. 967 Clutch Coil Check.......................................................................... 967 Pulley Installation........................................................................ 968 Clutch Assembly Installation............................................................... 968 EVACUATING THE SYSTEM.......................................................................... 969 CHARGING THE A/C SYSTEM........................................................................ 971 AIR CONDITIONER DRIVE BELT..................................................................... 971 Pulley Alignment........................................................................... 971 Belt Tension............................................................................... 972 TROUBLESHOOTING................................................................................ 973 Preliminary Checks......................................................................... 973 Diagnosis of Gauge Readings and System Performance......................................... 974 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................................. 975 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM............................................... 981 SECTION N5 OPERATOR CONTROLS.......................................................................... 982 OPERATOR CONTROLS.................................................................................. 984 STEERING WHEEL AND CONTROLS.................................................................... 985 STEERING WHEEL............................................................................. 985 HORN BUTTON................................................................................ 985 TILT/TELESCOPE LEVER....................................................................... 985 MULTI-FUNCTION TURN SIGNAL SWITCH.......................................................... 985 Turn Signal Operation.................................................................. 986 High Beam Headlight Operation.......................................................... 986 Windshield Wiper Operation............................................................. 986 STEERING COLUMN............................................................................ 986 Removal................................................................................ 986 Inspection............................................................................. 987 Installation........................................................................... 987 PEDALS......................................................................................... 987 SERVICE BRAKE PEDAL........................................................................ 987 DYNAMIC RETARDER PEDAL..................................................................... 988 Optional - Dual Function/Single Pedal.................................................. 988 THROTTLE PEDAL............................................................................. 988 OVERHEAD PANEL CONTROLS AND COMPONENTS......................................................... 989 GRADE/SPEED WARNING CHART.................................................................. 989 RADIO SPEAKERS............................................................................. 989 WINDSHIELD WIPERS.......................................................................... 989 WARNING ALARM BUZZER....................................................................... 989 CAB RADIO.................................................................................. 989 WARNING LIGHTS DIMMER CONTROL.............................................................. 989 WARNING/STATUS INDICATOR LIGHT PANEL....................................................... 989 AIR CLEANER VACUUM GAUGES.................................................................. 989 CENTER CONSOLE................................................................................. 990 TRUCK CONTROLS............................................................................. 991 F-N-R Selector Switch.................................................................. 991 Hoist Control Lever.................................................................... 991 Trolley Master Control Lever........................................................... 991 CONSOLE SWITCHES AND CONTROLS.............................................................. 991 Cigarette Lighter...................................................................... 991 Window Control Switches................................................................ 991 Engine Shutdown Switch................................................................. 991 Override Switch........................................................................ 992 Retard Speed Control (RSC) Switch...................................................... 992 Retard Speed Control (RSC) Dial........................................................ 992 Statex III Download Port............................................................... 993 Engine Diagnostic Port (CENSE)......................................................... 993 Engine Diagnostic Connectors........................................................... 993 Data Storage Button.................................................................... 993 Passenger Seat......................................................................... 993 PAYLOAD METER.............................................................................. 994 Payload Meter Download Connector....................................................... 994 CAB CLIMATE CONTROL............................................................................ 995 HEATER/AIR CONDITIONER VENTS............................................................... 995 HEATER/AIR CONDITIONER CONTROLS AND VENTS.................................................. 995 Defroster Vent Control Switch.......................................................... 995 Heat Control Switch.................................................................... 995 Temperature Control Knob............................................................... 995 Fan Control Knob....................................................................... 995 Heater/Air Conditioner Vents........................................................... 995 OPERATOR SEAT.................................................................................. 996 ADJUSTMENT................................................................................. 996 INSTRUMENT PANEL............................................................................... 997 GENERAL INFORMATION........................................................................ 997 CONTROL SYMBOLS............................................................................ 997 CONTROL SWITCHES AND GAUGES................................................................ 998 Key Switch............................................................................. 999 Engine Shutdown Switch With Timer Delay................................................ 999 Fog Light Switch....................................................................... 999 Ladder Light Switch.................................................................... 999 Backup Light Switch.................................................................... 999 Panel Illumination Lights.............................................................. 999 Cab Air Conditioner/Heater Vents....................................................... 999 Engine Cold Weather Starting Aid Switch................................................ 999 Rotating Beacon Light Switch...........................................................1000 Heated Mirror Switch...................................................................1000 Wheel Brake Lock Switch................................................................1000 Leakage Test Switch (Trolley Option Only)..............................................1000 Parking Brake Switch...................................................................1000 Digital Tachometer.....................................................................1000 Right Turn Signal Indicator Light......................................................1001 High Beam Headlight Indicator Light....................................................1001 Left Turn Signal Indicator Light.......................................................1001 Digital Speedometer/Payload Meter Display..............................................1001 Voltmeter Gauge........................................................................1001 Engine Oil Pressure Gauge..............................................................1001 Engine Water Temperature Gauge.........................................................1001 Fuel Gauge.............................................................................1001 Engine Hourmeter.......................................................................1002 Headlight Switch.......................................................................1002 Panel Illumination Lights Dimmer Rheostat..............................................1002 Payload Meter Switch...................................................................1002 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL................................................1003 INDICATOR LIGHT FUNCTIONS..................................................................1004 High Hydraulic Oil Temperature.........................................................1004 Low Steering Pressure..................................................................1004 Low Accumulator Precharge Pressure Warning.............................................1004 Electric System Fault Warning..........................................................1005 Low Brake Pressure Indicator...........................................................1005 Low Hydraulic Tank Level...............................................................1005 Low Automatic Lubrication System Pressure..............................................1005 Circuit Breaker Tripped................................................................1005 Hydraulic Oil Filter...................................................................1005 Low Fuel Indicator.....................................................................1006 Parking Brake Indicator................................................................1006 Service Brake Indicator................................................................1006 Body Up Indicator......................................................................1006 Dynamic Retarding Indicator............................................................1006 Stop Engine Warning....................................................................1006 Backup Indicator.......................................................................1006 Engine Shutdown Timer Switch- Five Minute Idle.........................................1006 Retard Speed Control...................................................................1006 Service Engine Indicator (AEM).........................................................1007 High Wheel Motor Temperature Indicator.................................................1007 Blower Fault Warning...................................................................1007 Service Engine Indicator (CENSE).......................................................1007 Komatsu Engines w/Centry™ Fuel Control.................................................1007 Hazard Warning Light Switch............................................................1007 Lamp Test Switch/Centry™ Diagnostic Test Switch........................................1007 Backup Lights..........................................................................1011 Retard Lights..........................................................................1011 Brake Light............................................................................1011 Backup Alarm...........................................................................1011 CENTRY™ FUEL SYSTEM DIAGNOSTICS................................................................1012 GENERAL OPERATION..........................................................................1012 DETERMINING FAULT CODES....................................................................1012 EXITING THE DIAGNOSTICS MODE...............................................................1013 SECTION P LUBRICATION AND SERVICE INDEX....................................................................1014 SECTION P2 LUBRICATION AND SERVICE INDEX...............................................................1016 LUBRICATION AND SERVICE............................................................................1018 GENERAL INFORMATION............................................................................1018 HYDRAULIC TANK SERVICE.........................................................................1018 Adding Oil.................................................................................1018 COOLING SYSTEM.................................................................................1019 Radiator Filling Procedure.................................................................1019 RESERVE ENGINE OIL SYSTEM - (OPTIONAL).........................................................1019 Reserve Oil Tank Filling Procedure (Remote Fill)...........................................1019 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS....................................................1021 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)........................................1022 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................................1023 100 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................1023 250 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................1024 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)........................................1025 500 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................1026 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)........................................1027 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................1028 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................1029 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................1029 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................1030 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................1031 SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX..........................................................1032 AUTOMATIC LUBRICATION SYSTEM.......................................................................1034 GENERAL DESCRIPTION............................................................................1034 SYSTEM COMPONENTS..............................................................................1035 Filter Assembly............................................................................1035 Hydraulic Motor and Grease Pump............................................................1035 Reservoir..................................................................................1035 Fixed Pressure Reducing Valve..............................................................1035 Flow Control Valve.........................................................................1035 Solenoid Valve.............................................................................1036 Vent Valve.................................................................................1036 24VDC Lubrication Cycle Timer..............................................................1036 Time Delay Module..........................................................................1036 Pump Cutoff Pressure Switch................................................................1036 Unloader Valve.............................................................................1036 Pressure Switch............................................................................1036 Pressure Gauge.............................................................................1036 Manual Override Button.....................................................................1036 Injectors..................................................................................1036 SYSTEM OPERATION...............................................................................1039 Normal Operation...........................................................................1039 Pressure Failure Detection Circuits........................................................1040 GENERAL INSTRUCTIONS...........................................................................1041 LUBRICANT REQUIRED FOR SYSTEM..............................................................1041 SYSTEM PRIMING.............................................................................1041 LUBRICANT PUMP.............................................................................1042 Pump Housing Oil Level.................................................................1042 Pump Pressure Control..................................................................1042 FILTER AND RESERVOIR.......................................................................1042 Filter Assembly Element................................................................1043 INJECTORS (SL-1 Series H)..................................................................1043 Injector Specifications................................................................1043 Injector Adjustment....................................................................1043 INJECTOR OPERATION.................................................................................1045 SYSTEM CHECKOUT................................................................................1046 Lubrication Cycle Timer Check..............................................................1046 Lubrication Cycle Timer Adjustment.........................................................1047 PREVENTIVE MAINTENANCE INSPECTION..............................................................1047 10 Hour Lubrication System Inspection......................................................1047 100 Hour Inspection........................................................................1047 250 Hour Inspection........................................................................1047 500 Hour Inspection........................................................................1048 1000 Hour Inspection.......................................................................1048 PUMP REBUILD...................................................................................1049 Disassembly................................................................................1049 Cleaning and Inspection....................................................................1049 Assembly...................................................................................1051 VENT VALVE REBUILD.............................................................................1052 Disassembly and Assembly...................................................................1052 SYSTEM TROUBLESHOOTING CHART...................................................................1053 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................1058 AXLE BOX...................................................................................1058 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................1059 ARMATURE AREA..............................................................................1059 AT TIRE CHANGE.............................................................................1059 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................1060 GENERATOR/ALTERNATOR.......................................................................1060 GRID BLOWER MOTOR..........................................................................1060 CONTROL EQUIPMENT CHECKS...................................................................1060 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................1061 VEHICLE OPERATIONS TESTS...................................................................1061 SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX..................................................1056 SECTION R SYSTEM SCHEMATICS...............................................................................1062 EF5755 BRAKE SCHEMATIC ................................................................................1063 EM1369 HYDRAULIC SCHEMATIC ............................................................................1064 XS1000 ELECTRICAL SCHEMATIC ...........................................................................1065
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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