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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30489 & A30490) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30489 & A30490
- PUBLICATION NUMBER:CEBM026200
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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30489 & A30490) KOMATSU 730E
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30489 & A30490) KOMATSU 730E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30489 & A30490) KOMATSU 730E
- This manual is written for use by the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
- All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service, and reassembly.
- Each major serviceable component has a section in the shop manual. Disassembly of any component should only be done as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning in metric units and in U.S. English units. All references to Right, Left, Front, or Rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements for common fasteners are shown in torque charts in the general information section. Special torque requirtements are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
- A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating. The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E).
- The three numbers represent the basic truck model. The letter E, when present, designates an electrical wheel motor drive system. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30489 & A30490) KOMATSU 730E
COVER ..................................................................................................... 1 FOREWORD................................................................................................... 5 TABLE OF CONTENTS.......................................................................................... 7 SECTION A GENERAL INFORMATION INDEX........................................................................ 9 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...................................................................... 55 SECTION A5 TORQUE TABLES AND CONVERSION CHARTS ........................................................ 65 SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX.................................................. 75 SHORT TERM IDLE PERIODS............................................................................ 77 PREPARATION FOR STORAGE............................................................................ 78 REMOVAL FROM STORAGE............................................................................... 79 RECONDITIONING AN IDLE VEHICLE..................................................................... 80 ENGINE OPERATION................................................................................... 83 After The Engine Has Started................................................................... 83 ENGINE STORAGE..................................................................................... 84 Temporary Storage (30 Days Or Less)............................................................ 84 Extended Storage (More Than 30 Days)........................................................... 85 RESTORING AN ENGINE AFTER EXTENDED STORAGE......................................................... 86 ELECTRIC DRIVE TRUCKS.............................................................................. 87 Storing A Truck That Is Operational............................................................ 87 Storing A Truck That Is Not Operational........................................................ 88 Storing A Major Component...................................................................... 89 Periodic Inspections........................................................................... 89 Placing Equipment Into Service After Storage................................................... 89 SECTION B STRUCTURES INDEX................................................................................. 91 SECTION B2 STRUCTURAL COMPONENTS INDEX................................................................. 93 STRUCTURAL COMPONENTS.............................................................................. 95 LADDERS........................................................................................ 95 Removal.................................................................................... 95 Installation............................................................................... 95 GRILLE AND HOOD................................................................................ 96 Removal.................................................................................... 96 Installation............................................................................... 96 RIGHT-HAND DECK................................................................................ 96 Removal.................................................................................... 96 Installation............................................................................... 98 CENTER DECK.................................................................................... 98 LEFT-HAND DECK................................................................................. 99 Removal.................................................................................... 99 Installation............................................................................... 99 SECTION B3 DUMP BODY INDEX.............................................................................101 DUMP BODY..........................................................................................103 Removal........................................................................................103 Installation...................................................................................104 BODY SLING.........................................................................................104 BODY PADS..........................................................................................105 BODY GUIDE.........................................................................................105 Adjustment.....................................................................................105 BODY POSITION INDICATOR............................................................................106 HOIST LIMIT SWITCH.................................................................................106 ROCK EJECTORS......................................................................................106 Inspection.....................................................................................106 SECTION B4 FUEL TANK INDEX.............................................................................107 FUEL TANK..........................................................................................109 Removal........................................................................................109 Repair.........................................................................................109 Cleaning.......................................................................................109 Installation...................................................................................110 FUEL GAUGE SENDER..................................................................................111 Removal........................................................................................111 Installation...................................................................................111 LOW FUEL SENDER....................................................................................112 Removal........................................................................................112 Installation...................................................................................112 TANK BREATHER VALVE................................................................................113 Removal........................................................................................113 Installation...................................................................................113 Disassembly....................................................................................113 Assembly.......................................................................................113 FUEL RECEIVER (WIGGINS QUICK FILL).................................................................114 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)............................................115 SECTION C ENGINE INDEX.....................................................................................117 SECTION C2 POWER MODULE INDEX..........................................................................119 POWER MODULE.......................................................................................121 GENERAL INFORMATION............................................................................121 POWER MODULE SERVICE...........................................................................122 Removal....................................................................................122 Installation...............................................................................126 SECTION C3 COOLING SYSTEM INDEX........................................................................129 COOLING SYSTEM.....................................................................................131 RADIATOR.......................................................................................131 Removal....................................................................................131 Service....................................................................................132 Installation...............................................................................132 RADIATOR FILL PROCEDURE........................................................................133 RADIATOR REPAIR................................................................................133 Internal Inspection........................................................................133 External Cleaning..........................................................................134 Disassembly................................................................................134 Cleaning and Inspection....................................................................135 Assembly...................................................................................135 Additional Service Information.............................................................137 PRESSURE TESTING...............................................................................137 COOLANT SYSTEM TROUBLESHOOTING.................................................................137 SECTION C4 POWER TRAIN INDEX...........................................................................139 POWER TRAIN........................................................................................141 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE..................................................141 General Information........................................................................141 Removal....................................................................................141 ALTERNATOR INSTALLATION........................................................................143 Engine/Alternator Mating...................................................................143 Alternator Measurement.....................................................................143 Engine End Play Measurement................................................................144 Determining Shim Requirements..............................................................145 Installing Alternator On Engine............................................................146 ENGINE.........................................................................................147 Removal....................................................................................147 Installation...............................................................................147 SECTION C5 AIR CLEANERS INDEX..........................................................................149 OPERATION..........................................................................................151 SERVICING THE AIR CLEANERS.........................................................................151 Replacing The Elements.........................................................................152 AIR CLEANER ASSEMBLY CLEANING......................................................................153 Primary Element Cleaning.......................................................................153 Precleaner Section Cleaning....................................................................155 AIR INTAKE TROUBLESHOOTING.........................................................................156 SECTION C7 FAN DRIVE CLUTCH INDEX......................................................................157 COMPONENTS.........................................................................................158 Input..........................................................................................158 Output.........................................................................................158 Stationary Components..........................................................................159 OPERATIONAL MODES..................................................................................160 Fully Engaged..................................................................................160 Modulated Variable Speed.......................................................................160 Fully Released.................................................................................161 Lubricating and Cooling Oil....................................................................162 MAINTENANCE........................................................................................163 TROUBLESHOOTING....................................................................................164 Preliminary Checks.............................................................................164 FIELD CHECK DIAGNOSIS..............................................................................165 Preliminary Checks - Engine Off................................................................165 Check Clutch Release...........................................................................165 Check Clutch Lock-up...........................................................................166 Overheating....................................................................................166 Thermal Sensor and Solenoid Valve..............................................................167 On Truck Test..................................................................................167 Off Truck Test.................................................................................167 FAN CLUTCH DISASSEMBLY INSTRUCTIONS................................................................172 REASSEMBLY OF THE FAN CLUTCH.......................................................................179 INSPECTION OF PARTS................................................................................190 REBUILD TOOLS......................................................................................194 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX...................................................195 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX..........................................................197 ELECTRICAL SYSTEM DESCRIPTION......................................................................199 BATTERIES..........................................................................................199 Maintenance and Service........................................................................199 Troubleshooting................................................................................199 BATTERY CHARGING ALTERNATOR........................................................................201 24VDC ELECTRIC START SYSTEM........................................................................201 CRANKING MOTORS................................................................................201 Removal....................................................................................201 Installation...............................................................................202 CRANKING MOTOR TROUBLESHOOTING.................................................................202 Preliminary Inspection.....................................................................203 No-Load Test...............................................................................203 Interpreting Results of Tests..............................................................203 Disassembly................................................................................204 Cleaning and Inspection....................................................................204 Armature Servicing.........................................................................205 Field Coil Checks..........................................................................207 Field Coil Removal.........................................................................207 Solenoid Checks............................................................................207 Test.......................................................................................207 Assembly...................................................................................209 Pinion Clearance...........................................................................210 MAGNETIC SWITCH................................................................................210 Coil Test..................................................................................210 Electric Start System Wiring Diagrams......................................................210 ENGINE PRELUB SYSTEM...............................................................................211 OPERATION......................................................................................211 Pressure Switch............................................................................211 Suction Line...............................................................................211 Outlet Line................................................................................211 Check Valve................................................................................211 Solenoid Timer.............................................................................211 TROUBLESHOOTING PRELUB STARTER CIRCUIT.............................................................213 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX....................................................217 PASSENGER SEAT BASE COMPARTMENT....................................................................219 COMPONENTS.........................................................................................219 Taillight Resistor Diode Assemblies............................................................219 Inclinometer...................................................................................219 Lubrication System Timer.......................................................................219 Three Minute Idle Timer Components.............................................................219 Three Minute Idle Timer........................................................................221 Idle Timer Relay...............................................................................221 Three Minute Idle Contactor....................................................................221 Three Minute Idle Circuit Test.................................................................221 Data Store Button..............................................................................221 Komatsu Engine Diagnostic Connector (Centry)...................................................221 Komatsu Engine Diagnostic Port (CENSE).........................................................221 STATEX III Propulsion System Diagnostic Connector..............................................221 Modular Mining Port (Optional).................................................................221 Alarm Indicating Device (AID) System...........................................................222 Diode Matrix (Without Sound)...................................................................222 Diode Matrix (With Sound)......................................................................223 Hot Switch Inverter............................................................................223 Hot Switch Inverter Card (Slot 4) (Not Used)...................................................223 Temperature....................................................................................223 Oil Level......................................................................................223 Temperature and Latch..........................................................................223 Coolant Level/Flasher..........................................................................224 Lamp Test......................................................................................224 BATTERY EQUALIZER BOX..............................................................................224 Troubleshooting................................................................................224 BODY POSITION SWITCHES.............................................................................226 Proximity Switch Operation.....................................................................226 Body-Up Switch Adjustment......................................................................227 Hoist Limit Switch Adjustment..................................................................227 24-VOLT RELAY AND DIODE BOARDS.....................................................................229 RELAY BOARDS.......................................................................................230 Description....................................................................................230 SERVICE............................................................................................230 To Replace A Relay:............................................................................230 To Replace A Circuit Breaker:..................................................................230 To Replace A Circuit Panel Card................................................................231 Relay Board Components.........................................................................231 Installing Additional Circuits.................................................................232 DIODE BOARD 1..................................................................................233 Diode Testing..................................................................................233 CIRCUIT BREAKERS...................................................................................235 SECTION D10 CHARGING SYSTEM INDEX......................................................................237 CHARGING SYSTEM DESCRIPTION........................................................................239 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION......................................................239 Excessive heat.................................................................................239 Dirt and dust..................................................................................239 Vibration......................................................................................239 PREVENTIVE MAINTENANCE PROCEDURES..................................................................240 Alternator Cleanliness.........................................................................240 Alternator Mounting............................................................................240 Belt Tension And Condition.....................................................................240 TROUBLESHOOTING PROCEDURES.........................................................................240 ALTERNATOR PERFORMANCE TEST........................................................................240 ALTERNATOR PERFORMANCE TEST - LOAD APPLIED.........................................................241 ALTERNATOR CABLE TEST..............................................................................241 VOLTAGE REGULATOR ADJUSTMENT.......................................................................242 ALTERNATOR.........................................................................................243 Removal........................................................................................243 Installation...................................................................................244 SECTION D35 PAYLOAD METER III INDEX....................................................................247 Introduction.......................................................................................252 Data Summary...................................................................................252 Data Gathering.................................................................................252 COMPONENT DESCRIPTION..............................................................................253 System Diagram.................................................................................253 Suspension Pressure Sensors....................................................................253 Inclinometer...................................................................................253 Operator Display...............................................................................253 Operator Switch................................................................................254 Speed Input....................................................................................254 Body-Up Switch.................................................................................254 Brake Lock Switch..............................................................................254 Payload Meter..................................................................................254 Communications Ports...........................................................................254 Key Switch Input...............................................................................255 Payload Meter Power............................................................................255 Load Lights....................................................................................255 Wiring and Termination.........................................................................256 TCI Outputs....................................................................................256 OPERATOR’S DISPLAY AND SWITCH......................................................................257 Reading the Speedometer........................................................................257 Reading the Load Display.......................................................................257 Using the Operator ID..........................................................................257 Using the Load and Ton Counter.................................................................257 Total Ton Counter..............................................................................257 Total Load Counter.............................................................................258 Clearing the Counters..........................................................................258 Viewing Live Sensor Data.......................................................................258 Other Display Messages.........................................................................258 PAYLOAD OPERATION & CALCULATION....................................................................259 Description of Haul Cycle States...............................................................259 Haul Cycle Description.........................................................................259 Load Calculation...............................................................................260 Carry Back.....................................................................................260 Measurement Accuracy...........................................................................260 SOURCES FOR PAYLOAD ERROR..........................................................................260 Payload Error..................................................................................260 Loading Conditions.............................................................................261 Pressure Sensors...............................................................................261 Swingloads.....................................................................................261 Speed and Distance.............................................................................261 HAUL CYCLE DATA....................................................................................261 Haul Cycle Warning Flags.......................................................................263 Frame Torque Data..............................................................................264 Sprung Weight Data.............................................................................264 Maximum Speed Data.............................................................................264 Alarm Records..................................................................................264 Fault Code Data................................................................................265 PC SOFTWARE OVERVIEW...............................................................................266 System Configuration...........................................................................266 Installing the PLMIII Software.................................................................266 DOWNLOADING DATA...................................................................................267 PLM III SYSTEM CONFIGURATION.......................................................................268 Starting Communications........................................................................268 Displayed Payload Units........................................................................268 Time Units.....................................................................................268 Connection Menu................................................................................268 Connecting to the Payload Meter................................................................269 Configure the Payload Meter....................................................................269 Setting the Date and Time......................................................................269 Setting the Truck Type.........................................................................270 Setting the Gauge Display Units................................................................270 Setting the Frame Serial Number................................................................270 Setting the Truck Number.......................................................................270 Setting the Komatsu Distributor................................................................270 Setting the Komatsu Customer...................................................................270 Setting the Overload Speed Limit Function......................................................271 Clean Truck Tare...............................................................................272 Inclinometer Calibration.......................................................................272 DATA ANALYSIS......................................................................................273 Creating a Query...............................................................................273 Sorting on Truck Unit Number...................................................................273 Sorting on Truck Type..........................................................................273 Sorting on Date Range..........................................................................274 Sorting on Time Range..........................................................................274 Payload Detail Screen..........................................................................275 Creating Reports...............................................................................275 Summary - one page report......................................................................276 Detailed - multi-page report...................................................................276 Creating Graphs................................................................................277 Exporting Data.................................................................................277 CSV Export.....................................................................................277 Compressed.....................................................................................278 Importing Data.................................................................................279 Deleting Haul Cycle Records....................................................................279 Viewing Alarms.................................................................................280 Deleting Alarm Records.........................................................................280 TROUBLESHOOTING SECTION............................................................................281 TROUBLESHOOTING................................................................................281 Viewing Active Alarms......................................................................281 Real-Time Data Display.....................................................................281 Testing the Payload Lights.................................................................281 Creating Log Files of Inputs...............................................................282 Daily Inspections..........................................................................282 Periodic Maintenance.......................................................................282 Abnormal Displays at Power-Up..............................................................283 No Payload Display When Key Switch is Turned ON............................................284 No Display on Speedometer..................................................................285 No Display on Operator Display.............................................................285 No Communications With PC..................................................................286 Load Lights Don’t Light During Loading.....................................................287 Load Lights Remain ON......................................................................288 Load Lights Remain ON During Dumping.......................................................288 Display Doesn't Clear When The Load Is Dumped..............................................288 Calibration Problems.......................................................................289 Alarm 1 - Left Front Pressure High.........................................................290 Alarm 2 - Left Front Pressure Low..........................................................290 Troubleshoot Wiring to Left Front Suspension...............................................290 Alarm 3 - Right Front Pressure High........................................................291 Alarm 4 - Right Front Pressure Low.........................................................291 Troubleshoot Wiring to Right Front Suspension..............................................291 Alarm 5 -Left Rear Pressure High...........................................................292 Alarm 6 - Left Rear Pressure Low...........................................................292 Troubleshoot Wiring to Left Rear Suspension................................................292 Alarm 7 - Right Rear Pressure High.........................................................293 Alarm 8 - Right Rear Pressure Low..........................................................293 Troubleshoot Wiring to Right Rear Suspension...............................................293 Alarm 9 - Inclinometer High................................................................294 Alarm 10 - Inclinometer Low................................................................294 Troubleshoot Inclinometer Wiring...........................................................294 Alarm 13 - Body Up Input Failure...........................................................295 Alarm 16 - Memory Write Failure............................................................296 Alarm 17 - Memory Read Failure.............................................................296 Alarm 18...................................................................................296 Alarm 19...................................................................................296 Alarm 22...................................................................................296 Operator Switch Doesn't Work...............................................................297 Alarm 26 - User Switch Fault - SELECT......................................................297 Alarm 27 - User Switch Fault - SET.........................................................297 Connector Map..............................................................................298 Connectors.................................................................................299 General Description........................................................................300 Tools Required.............................................................................300 Checkout Procedure.........................................................................300 PLMIII CHECKOUT PROCEDURE CONFIRMATION.........................................................304 Flashburn Programming......................................................................304 Confirmation Checklist.....................................................................306 SECTION E ELECTRICAL PROPULSION INDEX......................................................................307 SECTION E2 ELECTRICAL PROPULSION COMPONENTS INDEX......................................................309 GENERAL SYSTEM DESCRIPTION.........................................................................313 CONTROL SYSTEM.....................................................................................313 System Operation...............................................................................314 FL275 Panel....................................................................................315 CARD REPLACEMENT...................................................................................316 Removal........................................................................................316 Installation...................................................................................316 Card Repair....................................................................................316 Panel Wiring...................................................................................316 COMPUTER DESCRIPTION...............................................................................317 Microprocessor.................................................................................317 Download Capability............................................................................317 SOFTWARE...........................................................................................317 Base Monitor Program...........................................................................317 Runtime Monitor Program - OBJ Running Code.....................................................317 Configuration Software - CFG...................................................................318 PTU - Portable Test Unit Code..................................................................318 System Regulation..............................................................................318 Propulsion.....................................................................................319 Retarding......................................................................................319 TWO-DIGIT DISPLAY PANEL............................................................................320 The Coded Number...............................................................................320 Events.........................................................................................320 Frames.........................................................................................321 Windows........................................................................................321 System Categories..............................................................................321 Limits On Resetting Faults.....................................................................321 NA Faults......................................................................................322 Event Sequence.................................................................................322 Resetting Events...............................................................................322 Event Descriptions.............................................................................322 Subcode Descriptions...........................................................................322 PORTABLE TEST UNIT (PTU)...........................................................................333 DESCRIPTION....................................................................................333 Operational Hints..........................................................................333 SOFTWARE INSTALLATION PREPARATION..............................................................334 HARD DISK SPACE REQUIREMENTS...................................................................334 SOFTWARE INSTALLATION ON PTU...................................................................334 PTU/Truck Communication Problems...........................................................335 THE MAIN MENU..................................................................................336 Quit Menu..................................................................................336 PTU Talk To Truck..........................................................................336 View PTU Saved Files.......................................................................336 List Stat Data Files.......................................................................336 Truck Setup (CFG)..........................................................................336 Select Truck Setup.........................................................................336 Update CFG Version.........................................................................336 Change PTU Password........................................................................336 CONFIGURATION (CFG) FILE CONVERSION............................................................338 Conversion Procedure.......................................................................338 Convert Old CFG files for New software.....................................................339 STATEX CONFIGURATION FILES.....................................................................342 0) Source Directory: . . ..................................................................342 1) Select A Truck Configuration . . .......................................................343 2) View Truck Configuration: Data Curves . . ..............................................344 3) Change/View Serial and Model Numbers . . ...............................................345 4) View Options . . .......................................................................345 5) Change/View Truck Specifics . . ........................................................347 6) Change/View Overspeeds . . .............................................................349 7) Save a Truck Configuration, filename: . . ..............................................350 8) Save Directory: . . ....................................................................351 CHANGE PTU PASSWORD............................................................................352 PROGRAMMING THE TRUCK..........................................................................353 Connect PTU to the Truck...................................................................353 Select Configuration File..................................................................353 Activate The PTU Mode......................................................................353 Check Object Code Version..................................................................354 Download Configuration Files...............................................................355 Date And Time..............................................................................356 Event Data.................................................................................357 Statistical Data...........................................................................359 View Counters..............................................................................359 View Profiles..............................................................................359 Upload Statistical Data To A File..........................................................359 Statistical Data Codes - Counters..........................................................360 STATISTICAL DATA CODES - COUNTERS..............................................................361 STATISTICAL DATA CODES - PROFILES..............................................................366 TRUCK SPECIFIC INFORMATION.....................................................................370 Temporary Truck Settings...................................................................371 MISCELLANEOUS FEATURES.........................................................................372 Saving Data................................................................................372 PTU Abbreviations..........................................................................373 Other Menu Selections......................................................................373 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS.....................................................374 ALTERNATOR.....................................................................................374 ELECTRIC WHEEL MOTORS..........................................................................374 RETARDING GRIDS................................................................................374 ELECTRONIC ACCELERATOR AND RETARD PEDALS.......................................................374 Removal....................................................................................374 Installation...............................................................................374 Disassembly................................................................................375 Reassembly.................................................................................375 COOLING BLOWER WARNING SYSTEM..................................................................375 Operation..................................................................................375 Test.......................................................................................375 Removal....................................................................................376 Installation...............................................................................376 ELECTRICAL CONTROL CABINET.........................................................................377 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS.............................................382 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III.................................................383 2-DIGIT DISPLAY PANEL SUBCODES.....................................................................330 SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX.......................................385 GENERAL INFORMATION................................................................................389 COMMUNICATIONS PORT CHECK..........................................................................390 PTU Hookup.....................................................................................390 4.0 SEQUENCE TESTS - (ENGINE NOT ON)...............................................................391 Preparation and Setup..........................................................................391 CONTROL SYSTEM SELF-TEST.......................................................................392 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT.......................................................392 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT.........................................................393 PTU Setup..................................................................................393 4.3 REVERSER AND PROPULSION CONTACTORS CHECK...................................................394 4.4 NOT USED...................................................................................395 4.5 RETARD CONTACTORS OPERATION CHECK..........................................................395 4.6 GROUND FAULT SENSING CHECK.................................................................395 4.7 GROUND FAULT IN RETARD OPERATION CHECK.....................................................396 4.8 OVERRIDE OPERATION CHECK...................................................................396 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK..........................................................397 4.10 OVERSPEED RETARD OPERATION CHECK..........................................................397 4.11 HOIST INTERLOCK OPERATION CHECK...........................................................398 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK..................................................398 Return to Main Menu........................................................................398 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL...........................................399 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU..............................................399 5.2 DIGITAL INPUT CHECKS.......................................................................400 5.3 DIGITAL OUTPUT CHECKS......................................................................401 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL...................................................405 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU...................................................405 6.2 ANALOG INPUT CHECKS........................................................................406 6.3 FREQUENCY INPUT CHECKS.....................................................................410 Return to Main Menu........................................................................411 7.0 SPEED EVENT CHECKS.............................................................................411 Preparation and Setup..........................................................................411 Setup PTU......................................................................................411 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK....................................412 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK.........................412 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK........................412 7.4 OTHER SPEED EVENTS CHECKS..................................................................412 Return to Main Menu........................................................................412 8.0 RETARD SPEED CONTROL SYSTEM CHECK..............................................................413 Preparation and Setup..........................................................................413 Setup PTU......................................................................................413 8.1 OVERSPEED PICKUP AND DROPOUT CHECK.........................................................413 8.2 RETARD POT MAXIMUM SETTING CHECK...........................................................413 8.3 RETARD POT MINIMUM SETTING CHECK...........................................................413 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL.........................................414 Return to Main Menu........................................................................414 9.0 LOAD TEST USING TRUCK RETARD GRIDS.............................................................414 Setup and Preparation..........................................................................414 PTU Setup......................................................................................414 9.1 LOAD TEST..................................................................................415 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING........................................................415 Setup PTU......................................................................................415 10.1 RETARD CHECK..............................................................................416 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT...................................................417 11.1 BRAKE SYSTEM INTERLOCKS CHECK.............................................................417 Preparation................................................................................417 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT....................................................417 11.3 SYNC TRANSFORMER CHECKOUT.................................................................418 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT................................................418 11.5 BATTERY BOOST ADJUSTMENT..................................................................418 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST...............................................418 11.7 MOTOR ROTATION TEST.......................................................................419 11.8 GROUND FAULT CHECKS.......................................................................419 12.0 MISCELLANEOUS CHARTS..........................................................................420 12.1 WHEEL MOTOR GEAR RATIOS...................................................................420 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS............................................................421 12.3 ENGINE....................................................................................422 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX............................................................423 SECTION G2 TIRES AND RIMS INDEX........................................................................425 GENERAL INFORMATION................................................................................427 TIRES..............................................................................................427 Handling Tires.................................................................................427 Tire Maintenance...............................................................................428 Storing Tires After Removal....................................................................428 FRONT TIRES AND RIMS...............................................................................429 Removal........................................................................................429 Installation...................................................................................430 REAR TIRES AND RIMS................................................................................431 Removal........................................................................................431 Installation...................................................................................432 RIM............................................................................................433 Tire Removal...................................................................................433 RIM AND TIRE PREPARATION...........................................................................434 LUBRICANTS.........................................................................................434 TIRE INSTALLATION..................................................................................435 SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX...........................................................437 FRONT WHEEL HUB AND SPINDLE........................................................................439 WHEEL HUB AND SPINDLE ASSEMBLY.................................................................439 Removal....................................................................................439 Installation...............................................................................441 Disassembly................................................................................442 Cleaning and Inspection....................................................................443 Assembly...................................................................................443 Wheel Bearing Adjustment (Spindle Vertical)................................................446 Wheel Bearing Adjustment (Tire Mounted)....................................................447 Spindle Removal Procedure (Optional) (off of the truck)....................................450 STEERING CYLINDERS AND TIE ROD.................................................................452 Spherical Bearing Wear Limits..............................................................452 Removal....................................................................................453 Installation...............................................................................455 Bearing Replacement........................................................................455 TOE-IN ADJUSTMENT..............................................................................456 SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX.........................................................457 PIVOT PIN..........................................................................................459 Removal........................................................................................459 Installation...................................................................................460 PIVOT EYE BEARING..................................................................................460 Disassembly....................................................................................460 Assembly.......................................................................................461 PIVOT EYE REPAIR...................................................................................461 Removal........................................................................................461 Disassembly....................................................................................461 Bushing (New)..................................................................................461 Pivot Eye Bore (New)...........................................................................461 Assembly.......................................................................................461 Installation...................................................................................462 ANTI-SWAY BAR......................................................................................462 Removal........................................................................................462 Installation...................................................................................462 Disassembly....................................................................................463 Cleaning and Inspection........................................................................463 Assembly.......................................................................................463 SECTION G5 REAR AXLE HOUSING INDEX.....................................................................465 REAR AXLE HOUSING..................................................................................467 Removal........................................................................................467 Installation...................................................................................467 WHEEL MOTOR........................................................................................467 Removal........................................................................................467 Cleaning and Inspection........................................................................468 Installation...................................................................................468 Maximum Cap Screw Usage........................................................................468 SECTION H SUSPENSIONS INDEX................................................................................471 SECTION H2 FRONT SUSPENSION INDEX......................................................................473 Removal............................................................................................475 Installation.......................................................................................477 Angle Advance Tightening Procedure.................................................................478 Disassembly........................................................................................479 Cleaning and Inspection............................................................................480 Assembly (Bearing Only)............................................................................480 Suspension Assembly (Complete).....................................................................480 SUSPENSION PRESSURE TEST...........................................................................482 SECTION H3 REAR SUSPENSIONS INDEX......................................................................485 Removal............................................................................................488 Installation.......................................................................................490 Disassembly........................................................................................490 Cleaning and Inspection............................................................................491 Assembly...........................................................................................491 SUSPENSION PRESSURE TEST...........................................................................493 SECTION H4 OILING AND CHARGING PROCEDURES INDEX........................................................495 GENERAL............................................................................................497 EQUIPMENT LIST.....................................................................................497 Hydrair® Charging Kit..........................................................................497 Installation of Charging Kit...................................................................497 Removal of Charging Kit........................................................................498 Support Blocks For Oiling and Charging Dimensions..............................................498 FRONT SUSPENSION...................................................................................499 Front Suspension Oiling........................................................................499 Front Suspension Nitrogen Charging.............................................................500 REAR SUSPENSION....................................................................................502 Rear Suspension Oiling.........................................................................502 Rear Suspension Nitrogen Charging..............................................................504 SECTION J BRAKE CIRCUIT INDEX..............................................................................507 SECTION J2 BRAKE CIRCUIT INDEX.........................................................................509 GENERAL DESCRIPTION................................................................................511 SERVICE BRAKE CIRCUIT..............................................................................511 SECONDARY BRAKING AND AUTOMATIC APPLY..............................................................513 PARKING BRAKE CIRCUIT..............................................................................513 Normal Operation (key switch on, engine on)....................................................513 BRAKE LOCK CIRCUIT.................................................................................514 WARNING CIRCUIT....................................................................................514 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX.......................................................517 BRAKE VALVE........................................................................................519 Rebuild Criteria...............................................................................519 Removal........................................................................................520 Installation...................................................................................520 DISASSEMBLY........................................................................................522 Cleaning and Inspection........................................................................523 ASSEMBLY...........................................................................................525 Actuator Base Threaded Inserts.................................................................525 Boot and Cap...................................................................................525 Valve Body Seal Installation...................................................................526 Regulator Sleeve O-Ring Installation...........................................................526 Actuator Plunger O-ring Installation...........................................................526 Assembly of Valve..............................................................................526 DIFFERENTIAL PRESSURE SWITCH.......................................................................528 Disassembly....................................................................................528 Cleaning and Inspection........................................................................528 Assembly.......................................................................................528 VALVE BENCH TEST AND ADJUSTMENT....................................................................529 Test Set Up Procedure..........................................................................529 Brake Valve Output Pressure Adjustment.........................................................531 Differential Pressure Switch Test..............................................................532 Final Test and Adjustment......................................................................532 Installation Of Brake Pedal Actuator Assembly to Brake Valve...................................533 HYDRAULIC BRAKE ACCUMULATORS.......................................................................535 Brake Accumulator Bleed Down Procedure.........................................................535 Removal........................................................................................535 Installation...................................................................................535 Disassembly....................................................................................536 Cleaning and Inspection........................................................................537 Assembly.......................................................................................537 Leak Testing...................................................................................539 BRAKE ACCUMULATOR CHARGING.........................................................................540 Temperature During Precharge...................................................................542 ACCUMULATOR STORAGE................................................................................542 Installation...................................................................................543 Bladder Storage................................................................................543 BRAKE MANIFOLD.....................................................................................544 Removal........................................................................................544 Removal........................................................................................544 Installation...................................................................................545 Disassembly....................................................................................545 Cleaning and Inspection........................................................................545 Assembly.......................................................................................545 BRAKE CIRCUIT CHECK-OUT PROCEDURE..................................................................549 EQUIPMENT REQUIRED.................................................................................551 INITIAL SYSTEM SET-UP..............................................................................552 Parking Brake..................................................................................552 Service Brakes.................................................................................553 Brake Lock/Secondary...........................................................................553 Low Brake Pressure and Auto Apply..............................................................554 Reapplications.................................................................................554 Differential Pressure Switch...................................................................554 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING......................................................556 The Brakes are Locked, Service, and/or Parking.................................................556 Both Brake Circuits are Dragging...............................................................556 One Brake Circuit is Dragging..................................................................556 Brakes are Not Going to Full Pressure..........................................................556 A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off.........................556 Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released....557 Differential Pressure Warning Circuit is Not Operating.........................................557 A Low Brake Pressure Warning Occurs When Brakes are Applied....................................557 Low Pressure Warning Circuit Not Operating Properly............................................557 Low Pressure Warning is On Even Though System Pressure is Correct..............................558 Low Pressure Warning Comes On and Pressure is Low..............................................558 A Squeal is Heard When Controller is Operated..................................................558 Output Pressure At Controller is Correct but Brakes are Not Applying...........................558 Brake Pressures Drift Excessively While Pedal is Held Steady...................................558 Oil is Leaking Around the Pedal Base...........................................................558 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM.......................558 Low Pressure Warning is On Even Though System Pressure is Correct..............................559 Low Pressure Warning Comes On and Pressure is Low..............................................559 A Squeal is Heard When Controller is Operated..................................................559 Output Pressure At Controller is Correct but Brakes are Not Applying...........................559 Brake Pressures Drift Excessively While Pedal is Held Steady...................................559 Oil is Leaking Around the Pedal Base...........................................................559 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM.......................559 HYDRAULIC BRAKE SYSTEM DATA SHEET..................................................................560 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX.....................................................547 SECTION J5 FRONT DISC BRAKES INDEX.....................................................................563 BRAKE CALIPER......................................................................................565 Removal........................................................................................565 Installation...................................................................................566 Disassembly....................................................................................567 Cleaning and Inspection........................................................................567 Assembly.......................................................................................569 BRAKE LINING.......................................................................................569 Replacement....................................................................................569 FRONT SERVICE BRAKE BURNISHING.....................................................................571 BRAKE BLEEDING PROCEDURE.......................................................................572 REAR DISC BRAKES...................................................................................575 REAR BRAKES....................................................................................575 CALIPER, DISC, AND PARKING BRAKE...............................................................575 Removal....................................................................................575 Installation...............................................................................576 CALIPER PISTON.................................................................................578 Piston Assembly Removal....................................................................578 Inspection.................................................................................578 Piston Assembly Installation...............................................................579 FUNCTIONAL TEST OF PISTON ASSEMBLY.............................................................580 Return Spring Force........................................................................580 Built-In Clearance.........................................................................580 Grip Force.................................................................................582 Grip Force Measurement.....................................................................583 Spring Force Measurement...................................................................585 Disassembly of Piston Assembly.............................................................586 Assembly of Piston Assembly................................................................587 BENCH TEST.....................................................................................587 BRAKE LINING...................................................................................588 Replacement................................................................................588 SERVICE BRAKE BURNISHING...........................................................................591 SAFETY PRECAUTIONS.............................................................................591 Rear Brake Burnishing......................................................................592 BRAKE BLEEDING PROCEDURE.......................................................................593 Spring Force Measurement...................................................................594 SECTION J6 REAR BRAKES INDEX...........................................................................573 SECTION J7 PARKING BRAKE INDEX.........................................................................595 GENERAL INFORMATION................................................................................597 PARKING BRAKE CALIPER..............................................................................597 Lining Thickness Inspection....................................................................597 Removal........................................................................................598 Installation...................................................................................598 Parking Brake Adjustment.......................................................................599 Parking Brake Caliper Disassembly..............................................................600 Cleaning and Inspection........................................................................601 Parking Brake Caliper Assembly.................................................................602 PARKING BRAKE LINING REPLACEMENT...................................................................602 PARKING BRAKE BURNISH PROCEDURE....................................................................602 Lining Conditioning............................................................................602 BRAKE BLEEDING PROCEDURE...........................................................................603 SECTION L HYDRAULIC SYSTEM INDEX...........................................................................605 SECTION L2 HYDRAULIC SYSTEM OVERVIEW..................................................................607 HYDRAULIC SYSTEM OVERVIEW..........................................................................608 Hoist Circuit Operation........................................................................608 Steering, Brake and Pantograph Circuit Operation...............................................608 Axle Blower System Operation...................................................................608 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR..........................................................611 HYDRAULIC SYSTEM COMPONENT REPAIR..................................................................613 HOIST PUMP.....................................................................................613 Removal....................................................................................613 Installation...............................................................................615 Disassembly................................................................................615 Inspection.................................................................................618 Assembly...................................................................................619 PISTON PUMP................................................................................624 Removal................................................................................624 Installation...........................................................................625 Disassembly............................................................................627 Inspection of Parts....................................................................633 Assembly...............................................................................635 AXLE BLOWER HYDRAULIC MOTOR........................................................................640 Removal........................................................................................640 Installation...................................................................................640 Rear Axle Blower Housing.......................................................................640 Disassembly................................................................................640 Assembly...................................................................................641 Disassembly................................................................................643 Inspection.................................................................................645 Assembly...................................................................................646 Trouble Shooting...........................................................................647 Hand Wheel Control.............................................................................648 Disassembly................................................................................648 Assembly...................................................................................648 HYDRAULIC TANK.................................................................................650 Filling Instructions.......................................................................650 Removal....................................................................................651 Installation...............................................................................651 HYDRAULIC TANK STRAINER AND DIFFUSER...........................................................652 Removal....................................................................................652 Inspect and Clean..........................................................................653 Installation...............................................................................653 SECTION L4 STEERING CIRCUIT INDEX......................................................................655 STEERING CIRCUIT OPERATION.........................................................................657 COMPONENT DESCRIPTION..............................................................................658 Steering Control Valve.........................................................................658 Unloader Valve.................................................................................659 Bleed-Down Manifold Valve......................................................................659 Flow Amplifier.................................................................................664 FLOW AMPLIFIER SYSTEM OPERATION....................................................................665 No Steer.......................................................................................665 Steering Left..................................................................................667 Steering Right.................................................................................669 No Steer, External Shock Load..................................................................671 Steering Pump..................................................................................673 High Pressure Filter...........................................................................673 Accumulators...................................................................................673 Low Precharge Warning Switch...................................................................673 SECTION L5 STEERING CONTROL VALVE INDEX................................................................675 Removal............................................................................................677 Installation.......................................................................................678 STEERING CONTROL VALVE REBUILD.....................................................................679 Disassembly....................................................................................679 Cleaning and Inspection........................................................................680 Assembly.......................................................................................680 BRAKE / STEERING PUMP..............................................................................684 Removal........................................................................................684 Installation...................................................................................686 Disassembly....................................................................................687 Inspection of Parts............................................................................687 Assembly.......................................................................................689 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX.....................................................691 BLEED-DOWN MANIFOLD................................................................................693 Removal........................................................................................693 Installation...................................................................................693 ACCUMULATOR........................................................................................694 Removal........................................................................................694 Installation...................................................................................695 Disassembly....................................................................................696 Cleaning and Inspection........................................................................696 Assembly.......................................................................................697 Leak Testing...................................................................................698 STEERING ACCUMULATOR CHARGING......................................................................699 Temperature During Precharge...................................................................702 ACCUMULATOR STORAGE................................................................................703 Installation...................................................................................703 FLOW AMPLIFIER.....................................................................................704 Removal........................................................................................704 Installation...................................................................................704 Disassembly....................................................................................705 Assembly.......................................................................................708 STEERING CYLINDERS.................................................................................709 Disassembly....................................................................................709 Piston Seal and Bearing Installation...........................................................709 Cylinder Assembly..............................................................................709 Test...........................................................................................709 SECTION L7 HOIST CIRCUIT INDEX.........................................................................717 HOIST CIRCUIT OPERATION............................................................................719 COMPONENT DESCRIPTION..............................................................................720 Hydraulic Tank.................................................................................720 Hydraulic Pump.................................................................................720 High Pressure Filter...........................................................................720 Hoist Valve....................................................................................720 Hoist Pilot Valve..............................................................................721 Bleed-Down Manifold............................................................................722 Counterbalance Manifold........................................................................722 Hoist-Up Limit Solenoid........................................................................722 Pilot Operated Check Valve.....................................................................722 HOIST VALVE OPERATION..............................................................................724 Float Operation................................................................................724 Power Up Operation (Figure 7-6)................................................................726 Hold Operation (Figure 7-7)....................................................................728 Power Down Operation (Figure 7-8)..............................................................730 Float Operation (Figure 7-9)...................................................................732 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX........................................................735 HOIST VALVE........................................................................................737 Removal........................................................................................737 Installation...................................................................................737 O-Ring Replacement.............................................................................739 INLET SECTION......................................................................................740 Disassembly....................................................................................740 Cleaning and Inspection........................................................................741 Assembly.......................................................................................741 REAR SPOOL SECTION (WORK PORTS)....................................................................742 Disassembly....................................................................................742 Cleaning and Inspection........................................................................744 Assembly.......................................................................................744 HOIST PILOT VALVE..................................................................................746 Removal........................................................................................746 Installation...................................................................................746 Disassembly....................................................................................747 Cleaning and Inspection........................................................................748 Assembly.......................................................................................748 HOIST UP LIMIT SOLENOID VALVE......................................................................749 HOIST CYLINDERS....................................................................................750 Removal........................................................................................750 Installation...................................................................................751 Disassembly....................................................................................753 Cleaning and Inspection........................................................................754 SS1143 Tightening Tool - Assembly Drawing......................................................755 ASSEMBLY OF QUILL AND CYLINDER.....................................................................755 Quill Installation.............................................................................755 Installation Of Check Balls And Plugs In Quill.................................................756 Assembly of Cylinder...........................................................................758 Pressure Testing...............................................................................759 COUNTERBALANCE MANIFOLD............................................................................759 SECTION L9 HIGH PRESSURE FILTERS INDEX.................................................................761 HOIST CIRCUIT FILTER...............................................................................763 Filter Element Replacement.....................................................................763 Removal........................................................................................764 Installation...................................................................................764 Indicator Switch...............................................................................764 STEERING CIRCUIT FILTER............................................................................765 Filter Element Replacement.....................................................................765 Removal........................................................................................766 Installation...................................................................................766 Indicator Switch...............................................................................766 INDICATOR SWITCH...................................................................................766 Test Procedure.................................................................................766 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE..............................................................769 Initial Start Up and Flushing (Steps 5 - 22).......................................................770 Component Checkout and Adjustment (Steps 23 - 34)..................................................771 Adjustment Procedure for Hoist Counterbalance Cartridge Valve (Steps 34a-34l)......................773 Counterbalance Valve Adjustment (Steps f & g):.................................................774 Manifold reassembly (steps i through k):.......................................................774 Piston Pump and Axle Box Hydraulic Motor Adjustment (Steps 35 - 50)................................775 Oil Cleanliness Check..............................................................................776 Oil Sampling Location on Truck:................................................................776 Oil Sampling Process and Cleanliness Criteria:.................................................776 DISABLED TRUCK DUMPING PROCEDURE...................................................................777 HOOKUP.........................................................................................777 DUMPING PROCEDURE..............................................................................777 Raising the Body:..............................................................................777 Lowering the Body:.............................................................................777 SECTION M OPTIONS AND SPECIAL TOOLS INDEX..................................................................785 SECTION M4 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM INDEX..............................................787 SYSTEM ADJUSTMENT..................................................................................789 PUMP...............................................................................................792 Removal............................................................................................792 Disassembly........................................................................................792 Inspection.........................................................................................792 Assembly...........................................................................................792 Installation.......................................................................................792 BLOWER DRIVE MOTOR.................................................................................795 Removal............................................................................................795 Disassembly........................................................................................795 Inspection Of Parts................................................................................796 Assembly...........................................................................................797 Installation.......................................................................................798 BLOWER BEARING REPAIR..............................................................................798 Removal........................................................................................798 Replacement....................................................................................798 Assembly.......................................................................................799 AIR CLEANER........................................................................................799 Assembly.......................................................................................799 Removal........................................................................................799 Assembly.......................................................................................799 SECTION M7 HEATER OPTIONS INDEX........................................................................801 GENERAL INFORMATION................................................................................803 TROUBLESHOOTING....................................................................................803 HEATER ELEMENT.....................................................................................803 Removal........................................................................................803 Installation...................................................................................804 GENERAL............................................................................................805 Maintenance....................................................................................805 HEATING ELEMENT....................................................................................805 Removal........................................................................................805 Installation...................................................................................806 THERMOSTAT.........................................................................................806 Removal........................................................................................806 Installation...................................................................................806 GENERAL INFORMATION................................................................................807 TROUBLESHOOTING....................................................................................807 HEATER ELEMENT.....................................................................................807 Removal........................................................................................807 Installation...................................................................................808 SECTION M8 SPECIAL TOOLS..............................................................................809 NITROGEN CHARGING VALVE............................................................................809 ROLL-OUT ASSEMBLY..................................................................................809 EYE BOLT...........................................................................................809 OFFSET WRENCH......................................................................................810 TORQUE ADAPTER.....................................................................................810 HANDLE.............................................................................................810 SEAL INSTALLER.....................................................................................810 SLEEVE ALIGNMENT TOOLS.............................................................................811 QUICK DISCONNECT COUPLING..........................................................................811 HARNESS............................................................................................811 SEAL INSTALLATION RING.............................................................................811 BELT TENSION TESTER................................................................................812 BELT ALIGNMENT TOOL................................................................................812 SOCKETS AND ADAPTERS...............................................................................812 DUST CAPS..........................................................................................812 HYDRAULIC SYSTEM FLUSHING TOOLS....................................................................813 PAYLOAD DATA MANAGER...............................................................................813 HYDRAULIC SYSTEM VACUUM PUMP.......................................................................813 MISCELLANEOUS SERVICE TOOLS........................................................................814 BRAKE PISTON TOOL..................................................................................815 HIGH VOLTAGE TOOLS.................................................................................818 2000 VDC METER.....................................................................................818 GROUNDING STICKS...................................................................................818 BODY PAD SPACER TOOL...............................................................................819 RADIATOR SHUTTERS..................................................................................823 OPERATION......................................................................................823 Hydraulic Circuit..........................................................................823 Electrical Circuit:........................................................................824 MAINTENANCE AND REPAIR.........................................................................824 TROUBLESHOOTING................................................................................825 Hydraulic Troubleshooting..................................................................828 Electrical Troubleshooting.................................................................830 SECTION M19 RADIATOR SHUTTERS INDEX....................................................................821 SECTION N OPERATOR'S CAB INDEX.............................................................................831 SECTION N2 TRUCK CAB INDEX.............................................................................833 TRUCK CAB..........................................................................................836 TRUCK CAB......................................................................................836 Description................................................................................836 Removal....................................................................................837 Installation...............................................................................839 CAB DOOR.......................................................................................839 Removal....................................................................................839 Installation...............................................................................840 Door Adjustment............................................................................840 Door Jam Bolt Adjustment...................................................................840 Door Handle Plunger Adjustment.............................................................842 Replace Door Glass.........................................................................843 Replace Door Window Regulator..............................................................847 Replace Door Handle or Latch Assembly......................................................847 Door and Door Hinge Seal Replacement.......................................................848 Door Opening Seal Removal..................................................................848 Installation...............................................................................848 GLASS REPLACEMENT..............................................................................849 Adhesive-Bonded Windows....................................................................849 Recommended Tools/Supplies.................................................................849 Replacement Procedure......................................................................849 Windshield and Rear Glass..................................................................850 Removal....................................................................................850 Installation...............................................................................851 Removal and Installation of Operator Seat......................................................852 Inspection.................................................................................852 Removal....................................................................................852 Installation...............................................................................852 Removal and Installation of Passenger Seat.....................................................853 Removal....................................................................................853 Installation...............................................................................853 SECTION N3 CAB COMPONENTS INDEX........................................................................855 WINDSHIELD WIPERS..................................................................................857 WIPER MOTOR REPLACEMENT........................................................................857 Removal....................................................................................857 Installation...............................................................................857 WIPER ARM REPLACEMENT..........................................................................857 Removal....................................................................................857 Installation...............................................................................858 WIPER LINKAGE REPLACEMENT......................................................................858 Removal....................................................................................858 Installation...............................................................................859 WINDSHIELD WASHER..............................................................................859 Operation..................................................................................859 Service....................................................................................859 SEAT BELT......................................................................................860 Removal....................................................................................860 Installation...............................................................................860 SECTION N4 OPERATOR COMFORT INDEX......................................................................863 HEATER/AIR CONDITIONER.............................................................................867 CONTROLS.......................................................................................867 Operation..................................................................................867 Heater/Air Conditioner Vents...............................................................867 Defroster Vent Control Switch..............................................................867 Heat Control Switch........................................................................867 Temperature Control Knob...................................................................867 Fan Control Knob...........................................................................867 Heater/Air Conditioner Selector Switch.....................................................867 COMPONENTS.....................................................................................868 Circuit Breakers...........................................................................868 Relays.....................................................................................868 Heater Core................................................................................868 Fan Motor and Speed Control................................................................869 Test.......................................................................................869 Actuators..................................................................................869 Test.......................................................................................869 Cab Air Filter.............................................................................870 AIR CONDITIONING SYSTEM............................................................................872 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES......................................................873 PRINCIPLES OF REFRIGERATION....................................................................873 Air Conditioning...........................................................................873 Refrigeration - The Act of Cooling.........................................................874 The Refrigeration Cycle....................................................................874 AIR CONDITIONER SYSTEM COMPONENTS..............................................................875 Compressor (Refrigerant Pump)..............................................................875 Service Valves.............................................................................875 Receiver-Drier.............................................................................875 Condenser..................................................................................875 Expansion Block Valve......................................................................876 Accumulator................................................................................876 Evaporator.................................................................................877 ELECTRICAL CIRCUIT.............................................................................877 Thermostat.................................................................................877 Compressor Clutch..........................................................................878 Trinary™ Switch............................................................................878 SYSTEM SERVICING...............................................................................880 SERVICE TOOLS AND EQUIPMENT....................................................................881 Recovery/Recycle Station...................................................................881 Leak Detector..............................................................................882 Service Valves.............................................................................882 Vacuum Pump................................................................................882 Manifold Gauge Set.........................................................................883 Low Side Gauge.............................................................................883 High Side Gauge............................................................................883 Installing Manifold Gauge Set..............................................................884 Purging Air From Service Hoses.............................................................884 SYSTEM PERFORMANCE TEST........................................................................885 SYSTEM OIL.....................................................................................886 Handling and Reusing RPAG Oil..............................................................886 Oil Quantity...............................................................................886 Checking System Oil........................................................................886 REFRIGERANT....................................................................................887 Recycled Refrigerant.......................................................................887 Reclaimed Refrigerant......................................................................887 Refrigerant Quantity.......................................................................888 R-134a Refrigerant Containers..............................................................888 SYSTEM LEAK TESTING............................................................................888 Electronic Leak Detector...................................................................889 Tracer Dyes................................................................................889 Soap and Water.............................................................................889 RECOVERING AND RECYCLING THE REFRIGERANT.......................................................889 Performing the Recovery Cycle..............................................................889 Performing the Recycling Procedure.........................................................890 Evacuating and Charging the A/C System.....................................................890 SYSTEM REPAIR..................................................................................890 System Flushing............................................................................891 COMPONENT REPLACEMENT..........................................................................891 Hoses and Fittings.........................................................................891 Lines......................................................................................891 Expansion Valve............................................................................892 Receiver-Drier.............................................................................892 Thermostat.................................................................................892 Compressor.................................................................................892 Accumulator................................................................................893 Clutch.....................................................................................893 Servicing the Compressor Clutch............................................................894 Pulley Removal.............................................................................896 Clutch Coil Check..........................................................................896 Pulley Installation........................................................................897 Clutch Assembly Installation...............................................................897 EVACUATING THE SYSTEM..........................................................................898 CHARGING THE A/C SYSTEM........................................................................900 AIR CONDITIONER DRIVE BELT.....................................................................900 Pulley Alignment...........................................................................900 Belt Tension...............................................................................901 TROUBLESHOOTING................................................................................902 Preliminary Checks.........................................................................902 Diagnosis of Gauge Readings and System Performance.........................................903 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.................................................904 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM...............................................910 SECTION N5 OPERATOR CONTROLS..........................................................................911 OPERATOR CONTROLS..................................................................................913 STEERING WHEEL AND CONTROLS....................................................................914 STEERING WHEEL.............................................................................914 HORN BUTTON................................................................................914 TILT/TELESCOPE LEVER.......................................................................914 MULTI-FUNCTION TURN SIGNAL SWITCH..........................................................914 Turn Signal Operation..................................................................915 High Beam Headlight Operation..........................................................915 Windshield Wiper Operation.............................................................915 STEERING COLUMN............................................................................915 Removal................................................................................915 Inspection.............................................................................916 Installation...........................................................................916 PEDALS.........................................................................................916 SERVICE BRAKE PEDAL........................................................................916 DYNAMIC RETARDER PEDAL.....................................................................917 Optional - Dual Function/Single Pedal..................................................917 THROTTLE PEDAL.............................................................................917 OVERHEAD PANEL CONTROLS AND COMPONENTS.........................................................918 GRADE/SPEED WARNING CHART..................................................................918 RADIO SPEAKERS.............................................................................918 WINDSHIELD WIPERS..........................................................................918 WARNING ALARM BUZZER.......................................................................918 CAB RADIO..................................................................................918 WARNING LIGHTS DIMMER CONTROL..............................................................918 WARNING/STATUS INDICATOR LIGHT PANEL.......................................................918 AIR CLEANER VACUUM GAUGES..................................................................918 CENTER CONSOLE.................................................................................919 TRUCK CONTROLS.............................................................................920 F-N-R Selector Switch..................................................................920 Hoist Control Lever....................................................................920 Trolley Master Control Lever...........................................................920 CONSOLE SWITCHES AND CONTROLS..............................................................920 Cigarette Lighter......................................................................920 Window Control Switches................................................................920 Engine Shutdown Switch.................................................................920 Override Switch........................................................................921 Retard Speed Control (RSC) Switch......................................................921 Retard Speed Control (RSC) Dial........................................................921 Statex III Download Port...............................................................922 Engine Diagnostic Port (CENSE).........................................................922 Engine Diagnostic Connectors...........................................................922 Data Storage Button....................................................................922 Passenger Seat.........................................................................922 PAYLOAD METER..............................................................................923 Payload Meter Download Connector.......................................................923 CAB CLIMATE CONTROL............................................................................924 HEATER/AIR CONDITIONER VENTS...............................................................924 HEATER/AIR CONDITIONER CONTROLS AND VENTS..................................................924 Defroster Vent Control Switch..........................................................924 Heat Control Switch....................................................................924 Temperature Control Knob...............................................................924 Fan Control Knob.......................................................................924 Heater/Air Conditioner Vents...........................................................924 OPERATOR SEAT..................................................................................925 ADJUSTMENT.................................................................................925 INSTRUMENT PANEL...............................................................................926 GENERAL INFORMATION........................................................................926 CONTROL SYMBOLS............................................................................926 CONTROL SWITCHES AND GAUGES................................................................927 Key Switch.............................................................................928 Engine Shutdown Switch With Timer Delay................................................928 Fog Light Switch.......................................................................928 Ladder Light Switch....................................................................928 Backup Light Switch....................................................................928 Panel Illumination Lights..............................................................928 Cab Air Conditioner/Heater Vents.......................................................928 Engine Cold Weather Starting Aid Switch................................................928 Rotating Beacon Light Switch...........................................................929 Heated Mirror Switch...................................................................929 Wheel Brake Lock Switch................................................................929 Leakage Test Switch (Trolley Option Only)..............................................929 Parking Brake Switch...................................................................929 Digital Tachometer.....................................................................929 Right Turn Signal Indicator Light......................................................930 High Beam Headlight Indicator Light....................................................930 Left Turn Signal Indicator Light.......................................................930 Digital Speedometer/Payload Meter Display..............................................930 Voltmeter Gauge........................................................................930 Engine Oil Pressure Gauge..............................................................930 Engine Water Temperature Gauge.........................................................930 Fuel Gauge.............................................................................930 Engine Hourmeter.......................................................................931 Headlight Switch.......................................................................931 Panel Illumination Lights Dimmer Rheostat..............................................931 Payload Meter Switch...................................................................931 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL................................................932 INDICATOR LIGHT FUNCTIONS..................................................................933 High Hydraulic Oil Temperature.........................................................933 Low Steering Pressure..................................................................933 Low Accumulator Precharge Pressure Warning.............................................933 Electric System Fault Warning..........................................................934 Low Brake Pressure Indicator...........................................................934 Low Hydraulic Tank Level...............................................................934 Low Automatic Lubrication System Pressure..............................................934 Circuit Breaker Tripped................................................................934 Hydraulic Oil Filter...................................................................934 Low Fuel Indicator.....................................................................935 Parking Brake Indicator................................................................935 Service Brake Indicator................................................................935 Body Up Indicator......................................................................935 Dynamic Retarding Indicator............................................................935 Stop Engine Warning....................................................................935 Backup Indicator.......................................................................935 Engine Shutdown Timer Switch- Five Minute Idle.........................................935 Retard Speed Control...................................................................935 Service Engine Indicator (AEM).........................................................936 High Wheel Motor Temperature Indicator.................................................936 Blower Fault Warning...................................................................936 Service Engine Indicator (CENSE).......................................................936 Komatsu Engines w/Centry™ Fuel Control.................................................936 Hazard Warning Light Switch............................................................936 Lamp Test Switch/Centry™ Diagnostic Test Switch........................................936 Backup Lights..........................................................................940 Retard Lights..........................................................................940 Brake Light............................................................................940 Backup Alarm...........................................................................940 CENTRY™ FUEL SYSTEM DIAGNOSTICS................................................................941 GENERAL OPERATION..........................................................................941 DETERMINING FAULT CODES....................................................................941 EXITING THE DIAGNOSTICS MODE...............................................................942 SECTION P LUBRICATION AND SERVICE INDEX....................................................................943 SECTION P2 LUBRICATION AND SERVICE INDEX...............................................................945 GENERAL INFORMATION................................................................................947 HYDRAULIC TANK SERVICE.............................................................................947 Adding Oil.....................................................................................947 COOLANT LEVEL CHECK................................................................................948 Radiator Filling Procedure.....................................................................948 Coolant Specifications.........................................................................948 Unacceptable Practices.........................................................................948 WHEEL MOTOR SERVICE................................................................................948 RESERVE ENGINE OIL SYSTEM (Optional)...............................................................949 Reserve Oil Tank Filling Procedure (Remote fill)...............................................949 Inline Screen..................................................................................949 QUICK FILL SERVICE CENTER..........................................................................950 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS........................................................952 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)............................................953 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................954 100 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................954 250 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................955 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)............................................956 500 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................957 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)............................................958 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................................959 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................................960 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................................960 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................................961 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................................962 SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX..........................................................963 GENERAL DESCRIPTION................................................................................965 SYSTEM COMPONENTS..................................................................................966 Filter Assembly................................................................................966 Hydraulic Motor and Grease Pump................................................................966 Reservoir......................................................................................966 Fixed Pressure Reducing Valve..................................................................966 Flow Control Valve.............................................................................966 Solenoid Valve.................................................................................967 Vent Valve.....................................................................................967 24VDC Lubrication Cycle Timer..................................................................967 Time Delay Module..............................................................................967 Pump Cutoff Pressure Switch....................................................................967 Unloader Valve.................................................................................967 Pressure Switch................................................................................967 Manual Override Button.........................................................................967 Injectors......................................................................................967 SYSTEM OPERATION...................................................................................970 Normal Operation...............................................................................970 Pressure Failure Detection Circuits............................................................971 GENERAL INSTRUCTIONS...............................................................................972 LUBRICANT REQUIRED FOR SYSTEM..................................................................972 SYSTEM PRIMING.................................................................................972 LUBRICANT PUMP.................................................................................973 Pump Housing Oil Level.....................................................................973 Pump Pressure Control......................................................................973 FILTER AND RESERVOIR...........................................................................973 Filter Assembly Element....................................................................974 INJECTORS (SL-1 Series H)......................................................................974 Injector Specifications....................................................................974 Injector Adjustment........................................................................974 INJECTOR OPERATION.............................................................................976 SYSTEM CHECKOUT................................................................................977 Lubrication Cycle Timer Check..............................................................977 Lubrication Cycle Timer Adjustment.........................................................978 PREVENTIVE MAINTENANCE INSPECTION..............................................................978 10 Hour Lubrication System Inspection......................................................978 100 Hour Inspection........................................................................978 250 Hour Inspection........................................................................978 500 Hour Inspection........................................................................979 1000 Hour Inspection.......................................................................979 PUMP REBUILD...................................................................................980 Disassembly................................................................................980 Cleaning and Inspection....................................................................980 Assembly...................................................................................982 VENT VALVE REBUILD.............................................................................983 Disassembly and Assembly...................................................................983 SYSTEM TROUBLESHOOTING CHART...................................................................984 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................989 AXLE BOX.......................................................................................989 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................990 ARMATURE AREA..................................................................................990 AT TIRE CHANGE.................................................................................990 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................991 GENERATOR/ALTERNATOR...........................................................................991 GRID BLOWER MOTOR..............................................................................991 CONTROL EQUIPMENT CHECKS.......................................................................991 MOTORIZED WHEEL MAINTENANCE SCHEDULE...............................................................992 VEHICLE OPERATIONS TESTS.......................................................................992 SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX..................................................987 SECTION R SYSTEM SCHEMATICS INDEX ........................................................................993 EJ1735 HYDRAULIC BRAKE SYSTEM SCHEMATIC ...............................................................995 EK3630 HYDRAULIC SYSTEM SCHEMATIC......................................................................996 XS1000 ELECTRICAL SCHEMATIC............................................................................997
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