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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SNA30617 & UP) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30617 & UP
- PUBLICATION NUMBER:CEBM025000
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Description
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30617 & UP) KOMATSU 730E
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SNA30617 & UP) KOMATSU 730E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SNA30617 & UP) 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 (SNA30617 & UP) KOMATSU 730E
COVER ..................................................................................................... 1 FOREWORD................................................................................................... 5 TABLE OF CONTENTS.......................................................................................... 7 SECTION A GENERAL INFORMATION.............................................................................. 9 MAJOR COMPONENT DESCRIPTION............................................................................ 11 SPECIFICATIONS..................................................................................... 13 Komatsu SSA16V159.............................................................................. 13 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 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 WARNINGS AND CAUTIONS.................................................................................. 55 TORQUE TABLES AND CONVERSION CHARTS.................................................................... 65 STORAGE AND IDLE MACHINE PREPARATION INDEX............................................................. 75 STORAGE AND IDLE MACHINE PREPARATION............................................................... 77 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....................................................................................... 91 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 DUMP BODY INDEX........................................................................................ 101 DUMP BODY.......................................................................................... 103 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 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........................................................................................... 117 POWER MODULE INDEX .................................................................................... 119 POWER MODULE....................................................................................... 121 GENERAL INFORMATION............................................................................ 121 POWER MODULE SERVICE........................................................................... 122 Removal.................................................................................... 122 Installation............................................................................... 126 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 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 AIR CLEANERS INDEX..................................................................................... 149 AIR CLEANERS....................................................................................... 151 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 FAN DRIVE CLUTCH INDEX................................................................................. 157 FAN DRIVE CLUTCH................................................................................... 159 COMPONENTS..................................................................................... 159 Input...................................................................................... 159 Output..................................................................................... 159 Stationary Components...................................................................... 160 OPERATIONAL MODES.............................................................................. 161 Fully Engaged.............................................................................. 161 Modulated Variable Speed................................................................... 161 Fully Released............................................................................. 162 Lubricating and Cooling Oil................................................................ 163 MAINTENANCE.................................................................................... 164 TROUBLESHOOTING................................................................................ 165 Preliminary Checks......................................................................... 165 FIELD CHECK DIAGNOSIS.......................................................................... 166 Preliminary Checks - Engine Off............................................................ 166 Check Clutch Release....................................................................... 166 Check Clutch Lock-up....................................................................... 167 Overheating................................................................................ 167 Thermal Sensor and Solenoid Valve.......................................................... 168 On Truck Test.............................................................................. 168 Off Truck Test............................................................................. 168 TROUBLESHOOTING CHART.............................................................................. 170 FAN CLUTCH DISASSEMBLY INSTRUCTIONS................................................................ 173 REASSEMBLY OF THE FAN CLUTCH....................................................................... 180 INSPECTION OF PARTS................................................................................ 191 REBUILD TOOLS...................................................................................... 195 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION)......................................................... 197 24VDC ELECTRIC SUPPLY SYSTEM INDEX..................................................................... 199 24VDC ELECTRIC SUPPLY SYSTEM....................................................................... 201 ELECTRICAL SYSTEM DESCRIPTION.................................................................. 201 BATTERIES...................................................................................... 201 Maintenance and Service.................................................................... 201 Troubleshooting............................................................................ 201 BATTERY CHARGING ALTERNATOR.................................................................... 203 24VDC ELECTRIC START SYSTEM.................................................................... 203 CRANKING MOTORS............................................................................ 203 Removal................................................................................ 203 Installation........................................................................... 204 CRANKING MOTOR TROUBLESHOOTING............................................................. 204 Preliminary Inspection................................................................. 205 No-Load Test........................................................................... 205 Interpreting Results of Tests.......................................................... 205 Disassembly............................................................................ 206 Cleaning and Inspection................................................................ 206 Armature Servicing..................................................................... 207 Field Coil Checks...................................................................... 209 Field Coil Removal..................................................................... 209 Solenoid Checks........................................................................ 209 Test................................................................................... 209 Assembly............................................................................... 211 Pinion Clearance....................................................................... 212 MAGNETIC SWITCH............................................................................ 212 Coil Test.............................................................................. 212 Electric Start System Wiring Diagrams.................................................. 212 ENGINE PRELUB SYSTEM........................................................................... 213 OPERATION.................................................................................. 213 Pressure Switch........................................................................ 213 Suction Line........................................................................... 213 Outlet Line............................................................................ 213 Check Valve............................................................................ 213 Solenoid Timer......................................................................... 213 TROUBLESHOOTING PRELUB STARTER CIRCUIT......................................................... 215 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX.............................................................. 219 24VDC ELECTRICAL SYSTEM COMPONENTS................................................................. 221 PASSENGER SEAT BASE COMPARTMENT................................................................ 221 COMPONENTS..................................................................................... 221 Taillight Resistor Diode Assemblies........................................................ 221 Inclinometer............................................................................... 221 Lubrication System Timer................................................................... 221 Three Minute Idle Timer Components......................................................... 221 Three Minute Idle Timer.................................................................... 223 Idle Timer Relay........................................................................... 223 Three Minute Idle Contactor................................................................ 223 Three Minute Idle Circuit Test............................................................. 223 Data Store Button.......................................................................... 223 Komatsu Engine Diagnostic Connector (Centry)............................................... 223 Komatsu Engine Diagnostic Port (CENSE)..................................................... 223 STATEX III Propulsion System Diagnostic Connector.......................................... 223 Modular Mining Port (Optional)............................................................. 223 Alarm Indicating Device (AID) System....................................................... 224 Diode Matrix (Without Sound)............................................................... 224 Diode Matrix (With Sound).................................................................. 225 Hot Switch Inverter........................................................................ 225 Hot Switch Inverter Card (Slot 4) (Not Used)............................................... 225 Temperature................................................................................ 225 Oil Level.................................................................................. 225 Temperature and Latch...................................................................... 225 Coolant Level/Flasher...................................................................... 226 Lamp Test.................................................................................. 226 BATTERY EQUALIZER BOX.......................................................................... 226 Troubleshooting............................................................................ 226 BODY POSITION SWITCHES......................................................................... 228 Proximity Switch Operation................................................................. 228 Body-Up Switch Adjustment.................................................................. 229 Hoist Limit Switch Adjustment.............................................................. 229 24-VOLT RELAY AND DIODE BOARDS................................................................. 231 RELAY BOARDS................................................................................... 232 Description................................................................................ 232 SERVICE........................................................................................ 232 To Replace A Relay:........................................................................ 232 To Replace A Circuit Breaker:.............................................................. 232 To Replace A Circuit Panel Card............................................................ 233 Relay Board Components..................................................................... 233 Installing Additional Circuits............................................................. 234 DIODE BOARD 1.............................................................................. 235 Diode Testing.............................................................................. 235 CIRCUIT BREAKERS............................................................................... 237 CHARGING SYSTEM INDEX.................................................................................. 239 CHARGING SYSTEM.................................................................................... 241 CHARGING SYSTEM DESCRIPTION.................................................................... 241 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION.............................................. 241 Excessive heat......................................................................... 241 Dirt and dust.......................................................................... 241 Vibration.............................................................................. 241 PREVENTIVE MAINTENANCE PROCEDURES.......................................................... 242 Alternator Cleanliness................................................................. 242 Alternator Mounting.................................................................... 242 Belt Tension And Condition............................................................. 242 TROUBLESHOOTING PROCEDURES..................................................................... 242 ALTERNATOR PERFORMANCE TEST................................................................ 242 ALTERNATOR CABLE TEST...................................................................... 243 VOLTAGE REGULATOR ADJUSTMENT................................................................... 244 ALTERNATOR................................................................................. 245 Removal................................................................................ 245 Installation........................................................................... 246 PAYLOAD METER III INDEX................................................................................ 249 OPERATION SECTION.................................................................................. 254 Introduction................................................................................... 254 Data Summary............................................................................... 254 Data Gathering............................................................................. 254 COMPONENT DESCRIPTION.......................................................................... 255 System Diagram............................................................................. 255 Suspension Pressure Sensors................................................................ 255 Inclinometer............................................................................... 255 Operator Display........................................................................... 255 Operator Switch............................................................................ 256 Speed Input................................................................................ 256 Body-Up Switch............................................................................. 256 Brake Lock Switch.......................................................................... 256 Payload Meter.............................................................................. 256 Communications Ports....................................................................... 256 Key Switch Input........................................................................... 257 Payload Meter Power........................................................................ 257 Load Lights................................................................................ 257 Wiring and Termination..................................................................... 258 TCI Outputs................................................................................ 258 OPERATOR’S DISPLAY AND SWITCH.................................................................. 259 Reading the Speedometer.................................................................... 259 Reading the Load Display................................................................... 259 Using the Operator ID...................................................................... 259 Using the Load and Ton Counter............................................................. 259 Total Ton Counter.......................................................................... 259 Total Load Counter......................................................................... 260 Clearing the Counters...................................................................... 260 Viewing Live Sensor Data................................................................... 260 Other Display Messages..................................................................... 260 PAYLOAD OPERATION & CALCULATION................................................................ 261 Description of Haul Cycle States........................................................... 261 Haul Cycle Description..................................................................... 261 Load Calculation........................................................................... 262 Carry Back................................................................................. 262 Measurement Accuracy....................................................................... 262 SOURCES FOR PAYLOAD ERROR...................................................................... 262 Payload Error.............................................................................. 262 Loading Conditions......................................................................... 263 Pressure Sensors........................................................................... 263 Swingloads................................................................................. 263 Speed and Distance......................................................................... 263 HAUL CYCLE DATA................................................................................ 263 Haul Cycle Warning Flags................................................................... 265 Frame Torque Data.......................................................................... 266 Sprung Weight Data......................................................................... 266 Maximum Speed Data......................................................................... 266 Alarm Records.............................................................................. 266 Fault Code Data............................................................................ 267 PC SOFTWARE OVERVIEW........................................................................... 268 System Configuration....................................................................... 268 Installing the PLMIII Software............................................................. 268 DOWNLOADING DATA............................................................................... 269 PLM III SYSTEM CONFIGURATION................................................................... 270 Starting Communications.................................................................... 270 Displayed Payload Units.................................................................... 270 Time Units................................................................................. 270 Connection Menu............................................................................ 270 Connecting to the Payload Meter............................................................ 271 Configure the Payload Meter................................................................ 271 Setting the Date and Time.................................................................. 271 Setting the Truck Type..................................................................... 272 Setting the Gauge Display Units............................................................ 272 Setting the Frame Serial Number............................................................ 272 Setting the Truck Number................................................................... 272 Setting the Komatsu Distributor............................................................ 272 Setting the Komatsu Customer............................................................... 272 Setting the Overload Speed Limit Function.................................................. 273 Clean Truck Tare........................................................................... 274 Inclinometer Calibration................................................................... 274 DATA ANALYSIS.................................................................................. 275 Creating a Query........................................................................... 275 Sorting on Truck Unit Number............................................................... 275 Sorting on Truck Type...................................................................... 275 Sorting on Date Range...................................................................... 276 Sorting on Time Range...................................................................... 276 Payload Detail Screen...................................................................... 277 Creating Reports........................................................................... 277 Summary - one page report.................................................................. 278 Detailed - multi-page report............................................................... 278 Creating Graphs............................................................................ 279 Exporting Data............................................................................. 279 CSV Export................................................................................. 279 Compressed................................................................................. 280 Importing Data............................................................................. 281 Deleting Haul Cycle Records................................................................ 281 Viewing Alarms............................................................................. 282 Deleting Alarm Records..................................................................... 282 TROUBLESHOOTING SECTION............................................................................ 283 TROUBLESHOOTING................................................................................ 283 Viewing Active Alarms...................................................................... 283 Real-Time Data Display..................................................................... 283 Testing the Payload Lights................................................................. 284 Creating Log Files of Inputs............................................................... 284 Daily Inspections.......................................................................... 285 Periodic Maintenance....................................................................... 285 Abnormal Displays at Power-Up.............................................................. 285 No Payload Display When Key Switch is Turned ON............................................ 286 No Display on Speedometer.................................................................. 287 No Display on Operator Display............................................................. 287 No Communications With PC.................................................................. 288 Load Lights Don’t Light During Loading..................................................... 289 Load Lights Remain ON...................................................................... 290 Load Lights Remain ON During Dumping....................................................... 290 Display Doesn't Clear When The Load Is Dumped.............................................. 290 Calibration Problems....................................................................... 291 Alarm 1 - Left Front Pressure High......................................................... 293 Alarm 2 - Left Front Pressure Low.......................................................... 293 Troubleshoot Wiring to Left Front Suspension............................................... 293 Alarm 3 - Right Front Pressure High........................................................ 294 Alarm 4 - Right Front Pressure Low......................................................... 294 Troubleshoot Wiring to Right Front Suspension.............................................. 294 Alarm 5 -Left Rear Pressure High........................................................... 295 Alarm 6 - Left Rear Pressure Low........................................................... 295 Troubleshoot Wiring to Left Rear Suspension................................................ 295 Alarm 7 - Right Rear Pressure High......................................................... 296 Alarm 8 - Right Rear Pressure Low.......................................................... 296 Troubleshoot Wiring to Right Rear Suspension............................................... 296 Alarm 9 - Inclinometer High................................................................ 297 Alarm 10 - Inclinometer Low................................................................ 297 Troubleshoot Inclinometer Wiring........................................................... 297 Alarm 13 - Body Up Input Failure........................................................... 298 Alarm 16 - Memory Write Failure............................................................ 299 Alarm 17 - Memory Read Failure............................................................. 299 Alarm 18................................................................................... 300 Alarm 19................................................................................... 300 Alarm 22................................................................................... 300 Operator Switch Doesn't Work............................................................... 301 Alarm 26 - User Switch Fault - SELECT...................................................... 301 Alarm 27 - User Switch Fault - SET......................................................... 301 Connector Map.............................................................................. 302 Connectors................................................................................. 302 PLMIII CHECK OUT PROCEDURE......................................................................... 303 General Description............................................................................ 303 Tools Required................................................................................. 303 Checkout Procedure............................................................................. 303 PLMIII CHECKOUT PROCEDURE CONFIRMATION......................................................... 307 Flashburn Programming...................................................................... 307 Confirmation Checklist..................................................................... 309 SECTION E ELECTRICAL PROPULSION............................................................................ 311 ELECTRICAL PROPULSION COMPONENTS INDEX................................................................. 313 ELECTRICAL PROPULSION COMPONENTS................................................................... 317 PORTABLE TEST UNIT (PTU)....................................................................... 337 DESCRIPTION................................................................................ 337 Operational Hints...................................................................... 337 SOFTWARE INSTALLATION PREPARATION.......................................................... 338 HARD DISK SPACE REQUIREMENTS............................................................... 338 SOFTWARE INSTALLATION ON PTU............................................................... 338 PTU/Truck Communication Problems....................................................... 339 THE MAIN MENU.............................................................................. 340 Quit Menu.............................................................................. 340 PTU Talk To Truck...................................................................... 340 View PTU Saved Files................................................................... 340 List Stat Data Files................................................................... 340 Truck Setup (CFG)...................................................................... 340 Select Truck Setup..................................................................... 340 Update CFG Version..................................................................... 340 Change PTU Password.................................................................... 340 CONFIGURATION (CFG) FILE CONVERSION........................................................ 342 Conversion Procedure................................................................... 342 Convert Old CFG files for New software................................................. 343 STATEX CONFIGURATION FILES................................................................. 346 0) Source Directory: . . .............................................................. 346 1) Select A Truck Configuration . . ................................................... 347 2) View Truck Configuration: Data Curves . . .......................................... 348 3) Change/View Serial and Model Numbers . . ........................................... 349 4) View Options . . ................................................................... 349 5) Change/View Truck Specifics . . .................................................... 351 6) Change/View Overspeeds . . ......................................................... 353 7) Save a Truck Configuration, filename: . . .......................................... 354 8) Save Directory: . . ................................................................ 355 CHANGE PTU PASSWORD........................................................................ 356 PROGRAMMING THE TRUCK...................................................................... 357 Connect PTU to the Truck............................................................... 357 Select Configuration File.............................................................. 357 Activate The PTU Mode.................................................................. 357 Check Object Code Version.............................................................. 358 Download Configuration Files........................................................... 359 Date And Time.......................................................................... 360 Event Data............................................................................. 361 Statistical Data....................................................................... 363 View Counters.......................................................................... 363 View Profiles.......................................................................... 363 Upload Statistical Data To A File...................................................... 363 Statistical Data Codes - Counters...................................................... 364 STATISTICAL DATA CODES - COUNTERS.......................................................... 365 STATISTICAL DATA CODES - PROFILES.......................................................... 370 TRUCK SPECIFIC INFORMATION................................................................. 374 Temporary Truck Settings............................................................... 375 MISCELLANEOUS FEATURES..................................................................... 376 Saving Data............................................................................ 376 PTU Abbreviations...................................................................... 377 Other Menu Selections.................................................................. 377 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS................................................. 378 ALTERNATOR................................................................................. 378 ELECTRIC WHEEL MOTORS...................................................................... 378 RETARDING GRIDS............................................................................ 378 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................... 378 Removal................................................................................ 378 Installation........................................................................... 378 Disassembly............................................................................ 379 Reassembly............................................................................. 379 COOLING BLOWER WARNING SYSTEM.............................................................. 379 Operation.............................................................................. 379 Test................................................................................... 379 Removal................................................................................ 380 Installation........................................................................... 380 ELECTRICAL CONTROL CABINET..................................................................... 381 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS......................................... 386 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III............................................. 387 GENERAL SYSTEM DESCRIPTION..................................................................... 317 CONTROL SYSTEM................................................................................. 317 System Operation........................................................................... 318 FL275 Panel................................................................................ 319 CARD REPLACEMENT............................................................................... 320 Removal.................................................................................... 320 Installation............................................................................... 320 Card Repair................................................................................ 320 Panel Wiring............................................................................... 320 COMPUTER DESCRIPTION........................................................................... 321 Microprocessor............................................................................. 321 Download Capability........................................................................ 321 SOFTWARE....................................................................................... 321 Base Monitor Program....................................................................... 321 Runtime Monitor Program - OBJ Running Code................................................. 321 Configuration Software - CFG............................................................... 322 PTU - Portable Test Unit Code.............................................................. 322 System Regulation.......................................................................... 322 Propulsion................................................................................. 323 Retarding.................................................................................. 323 TWO-DIGIT DISPLAY PANEL........................................................................ 324 The Coded Number........................................................................... 324 Events..................................................................................... 324 Frames..................................................................................... 325 Windows.................................................................................... 325 System Categories.......................................................................... 325 Limits On Resetting Faults................................................................. 325 NA Faults.................................................................................. 326 Event Sequence............................................................................. 326 Resetting Events........................................................................... 326 Event Descriptions......................................................................... 326 Subcode Descriptions....................................................................... 326 2-DIGIT DISPLAY PANEL SUBCODES................................................................. 334 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX.................................................. 389 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.................................................... 393 GENERAL INFORMATION............................................................................ 393 COMMUNICATIONS PORT CHECK...................................................................... 394 PTU Hookup................................................................................. 394 4.0 SEQUENCE TESTS - (ENGINE NOT ON)........................................................... 395 Preparation and Setup...................................................................... 395 CONTROL SYSTEM SELF-TEST................................................................... 396 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT................................................... 396 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT..................................................... 397 PTU Setup.............................................................................. 397 4.3 REVERSER AND PROPULSION CONTACTORS CHECK............................................... 398 4.4 NOT USED............................................................................... 399 4.5 RETARD CONTACTORS OPERATION CHECK...................................................... 399 4.6 GROUND FAULT SENSING CHECK............................................................. 399 4.7 GROUND FAULT IN RETARD OPERATION CHECK................................................. 400 4.8 OVERRIDE OPERATION CHECK............................................................... 400 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK...................................................... 401 4.10 OVERSPEED RETARD OPERATION CHECK...................................................... 401 4.11 HOIST INTERLOCK OPERATION CHECK....................................................... 402 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.............................................. 402 Return to Main Menu.................................................................... 402 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL....................................... 403 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.......................................... 403 5.2 DIGITAL INPUT CHECKS................................................................... 404 5.3 DIGITAL OUTPUT CHECKS.................................................................. 405 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL............................................... 409 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU............................................... 409 6.2 ANALOG INPUT CHECKS.................................................................... 410 6.3 FREQUENCY INPUT CHECKS................................................................. 414 Return to Main Menu.................................................................... 415 7.0 SPEED EVENT CHECKS......................................................................... 415 Preparation and Setup...................................................................... 415 Setup PTU.................................................................................. 415 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK................................ 416 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK..................... 416 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK.................... 416 7.4 OTHER SPEED EVENTS CHECKS.............................................................. 416 Return to Main Menu.................................................................... 416 8.0 RETARD SPEED CONTROL SYSTEM CHECK.......................................................... 417 Preparation and Setup...................................................................... 417 Setup PTU.................................................................................. 417 8.1 OVERSPEED PICKUP AND DROPOUT CHECK..................................................... 417 8.2 RETARD POT MAXIMUM SETTING CHECK....................................................... 417 8.3 RETARD POT MINIMUM SETTING CHECK....................................................... 417 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL..................................... 418 Return to Main Menu.................................................................... 418 9.0 LOAD TEST USING TRUCK RETARD GRIDS......................................................... 418 Setup and Preparation...................................................................... 418 PTU Setup.................................................................................. 418 9.1 LOAD TEST.............................................................................. 419 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING.................................................... 419 Setup PTU.................................................................................. 419 10.1 RETARD CHECK.......................................................................... 420 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT............................................... 421 11.1 BRAKE SYSTEM INTERLOCKS CHECK......................................................... 421 Preparation............................................................................ 421 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT................................................ 421 11.3 SYNC TRANSFORMER CHECKOUT............................................................. 422 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT............................................ 422 11.5 BATTERY BOOST ADJUSTMENT.............................................................. 422 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST........................................... 422 11.7 MOTOR ROTATION TEST................................................................... 423 11.8 GROUND FAULT CHECKS................................................................... 423 12.0 MISCELLANEOUS CHARTS...................................................................... 424 12.1 WHEEL MOTOR GEAR RATIOS............................................................... 424 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS........................................................ 425 12.3 ENGINE................................................................................ 426 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS.................................................................. 427 TIRES AND RIMS INDEX.................................................................................. 429 TIRES AND RIMS..................................................................................... 431 GENERAL INFORMATION............................................................................ 431 TIRES.......................................................................................... 431 Handling Tires............................................................................. 431 Tire Maintenance........................................................................... 432 Storing Tires After Removal................................................................ 432 FRONT TIRES AND RIMS........................................................................... 433 Removal.................................................................................... 433 Installation............................................................................... 434 REAR TIRES AND RIMS............................................................................ 435 Removal.................................................................................... 435 Installation............................................................................... 436 RIM........................................................................................ 437 Tire Removal............................................................................... 437 RIM AND TIRE PREPARATION....................................................................... 438 LUBRICANTS..................................................................................... 438 TIRE INSTALLATION.............................................................................. 439 FRONT WHEEL HUB AND SPINDLE INDEX..................................................................... 441 FRONT WHEEL HUB AND SPINDLE........................................................................ 443 WHEEL HUB AND SPINDLE ASSEMBLY................................................................. 443 Removal.................................................................................... 443 Installation............................................................................... 445 Disassembly................................................................................ 446 Cleaning and Inspection.................................................................... 447 Assembly................................................................................... 447 Wheel Bearing Adjustment (Spindle Vertical)................................................ 450 Wheel Bearing Adjustment (Tire Mounted).................................................... 451 Spindle Removal Procedure (Optional) (off of the truck).................................... 454 STEERING CYLINDERS AND TIE ROD................................................................. 456 Spherical Bearing Wear Limits.............................................................. 456 Removal.................................................................................... 457 Installation............................................................................... 459 Bearing Replacement........................................................................ 459 TOE-IN ADJUSTMENT.............................................................................. 460 REAR AXLE HOUSING ATTACHMENTS INDEX.................................................................... 461 REAR AXLE HOUSING.................................................................................. 463 PIVOT PIN...................................................................................... 463 Removal.................................................................................... 463 Installation............................................................................... 464 PIVOT EYE BEARING.............................................................................. 464 Disassembly................................................................................ 464 Assembly................................................................................... 465 PIVOT EYE REPAIR............................................................................... 465 Removal.................................................................................... 465 Disassembly................................................................................ 465 Bushing (New).............................................................................. 465 Pivot Eye Bore (New)....................................................................... 465 Assembly................................................................................... 465 Installation............................................................................... 466 ANTI-SWAY BAR.................................................................................. 466 Removal.................................................................................... 466 Installation............................................................................... 466 Disassembly................................................................................ 467 Cleaning and Inspection.................................................................... 467 Assembly................................................................................... 467 REAR AXLE HOUSING INDEX................................................................................ 469 REAR AXLE HOUSING.................................................................................. 471 REAR AXLE HOUSING.............................................................................. 471 Removal.................................................................................... 471 Installation............................................................................... 471 WHEEL MOTOR.................................................................................... 471 Removal.................................................................................... 471 Cleaning and Inspection.................................................................... 472 Installation............................................................................... 472 Maximum Cap Screw Usage.................................................................... 472 SECTION H SUSPENSIONS...................................................................................... 475 FRONT SUSPENSION INDEX................................................................................. 477 FRONT SUSPENSION................................................................................... 479 Removal........................................................................................ 479 Installation................................................................................... 481 Angle Advance Tightening Procedure............................................................. 482 Disassembly.................................................................................... 483 Cleaning and Inspection........................................................................ 484 Assembly (Bearing Only)........................................................................ 484 Suspension Assembly (Complete)................................................................. 484 SUSPENSION PRESSURE TEST....................................................................... 486 REAR SUSPENSIONS INDEX................................................................................. 489 REAR SUSPENSIONS................................................................................... 491 Removal........................................................................................ 492 Installation................................................................................... 494 Disassembly.................................................................................... 494 Cleaning and Inspection........................................................................ 495 Assembly....................................................................................... 495 SUSPENSION PRESSURE TEST....................................................................... 497 OILING AND CHARGING PROCEDURES INDEX................................................................... 499 OILING AND CHARGING PROCEDURE...................................................................... 501 GENERAL........................................................................................ 501 EQUIPMENT LIST................................................................................. 501 Hydrair® Charging Kit...................................................................... 501 Installation of Charging Kit............................................................... 501 Removal of Charging Kit.................................................................... 502 Support Blocks For Oiling and Charging Dimensions.......................................... 502 FRONT SUSPENSION............................................................................... 503 Front Suspension Oiling.................................................................... 503 Front Suspension Nitrogen Charging......................................................... 504 REAR SUSPENSION................................................................................ 506 Rear Suspension Oiling..................................................................... 506 Rear Suspension Nitrogen Charging.......................................................... 508 OIL AND NITROGEN SPECIFICATIONS CHART.............................................................. 509 SECTION J BRAKE CIRCUIT ................................................................................... 511 BRAKE CIRCUIT INDEX.................................................................................... 513 BRAKE CIRCUIT...................................................................................... 515 GENERAL DESCRIPTION............................................................................ 515 SERVICE BRAKE CIRCUIT.......................................................................... 515 SECONDARY BRAKING AND AUTOMATIC APPLY.......................................................... 517 PARKING BRAKE CIRCUIT.......................................................................... 517 Normal Operation (key switch on, engine on)................................................ 517 BRAKE LOCK CIRCUIT............................................................................. 518 WARNING CIRCUIT................................................................................ 518 BRAKE CIRCUIT COMPONENT SERVICE INDEX.................................................................. 521 BRAKE CIRCUIT COMPONENT SERVICE.................................................................... 523 BRAKE VALVE.................................................................................... 523 Rebuild Criteria........................................................................... 523 Removal.................................................................................... 523 Installation............................................................................... 525 Disassembly................................................................................ 527 Cleaning and Inspection.................................................................... 529 ASSEMBLY....................................................................................... 529 Actuator Base Threaded Inserts............................................................. 529 Boot and Cap............................................................................... 529 Valve Body Seal Installation............................................................... 530 Regulator Sleeve O-Ring Installation....................................................... 531 Actuator Plunger O-Ring Installation....................................................... 531 Assembly of Valve.......................................................................... 531 DIFFERENTIAL PRESSURE SWITCH................................................................... 532 Disassembly................................................................................ 533 Cleaning and Inspection.................................................................... 533 Assembly................................................................................... 533 VALVE BENCH TEST AND ADJUSTMENT................................................................ 533 Test Set Up Procedure...................................................................... 535 Brake Valve Output Pressure Adjustment..................................................... 535 Differential Pressure Switch Test.......................................................... 536 Final Test and Adjustment.................................................................. 536 Installation Of Brake Pedal Actuator Assembly to Brake Valve............................... 537 HYDRAULIC BRAKE ACCUMULATORS................................................................... 539 Brake Accumulator Bleed-Down Procedure..................................................... 539 Removal.................................................................................... 539 Installation............................................................................... 541 Disassembly................................................................................ 541 Cleaning and Inspection.................................................................... 543 Assembly................................................................................... 543 Leak Testing............................................................................... 546 BRAKE ACCUMULATOR CHARGING..................................................................... 547 Temperature During Precharge............................................................... 549 ACCUMULATOR STORAGE............................................................................ 549 Installation............................................................................... 550 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX................................................................ 551 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................................. 553 EQUIPMENT REQUIRED............................................................................. 556 INITIAL SYSTEM SET-UP.......................................................................... 557 Parking Brake.............................................................................. 557 Service Brakes............................................................................. 558 Brake Lock/Secondary....................................................................... 558 Low Brake Pressure and Auto Apply.......................................................... 559 Reapplications............................................................................. 559 Differential Pressure Switch............................................................... 559 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...................................................... 561 The Brakes are Locked, Service, and/or Parking................................................. 561 Both Brake Circuits are Dragging............................................................... 561 One Brake Circuit is Dragging.................................................................. 561 Brakes are Not Going to Full Pressure.......................................................... 561 A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off......................... 561 Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released.... 562 Differential Pressure Warning Circuit is Not Operating......................................... 562 A Low Brake Pressure Warning Occurs When Brakes are Applied.................................... 562 Low Pressure Warning Circuit Not Operating Properly............................................ 562 Low Pressure Warning is On Even Though System Pressure is Correct.............................. 563 Low Pressure Warning Comes On and Pressure is Low.............................................. 563 A Squeal is Heard When Controller is Operated.................................................. 563 Output Pressure At Controller is Correct but Brakes are Not Applying........................... 563 Brake Pressures Drift Excessively While Pedal is Held Steady................................... 563 Oil is Leaking Around the Pedal Base........................................................... 563 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM....................... 563 CHECK-OUT PROCEDURE................................................................................ 564 HYDRAULIC BRAKE SYSTEM DATA SHEET.................................................................. 564 FRONT DISC BRAKES INDEX................................................................................ 567 FRONT DISC BRAKES.................................................................................. 569 BRAKE CALIPER.................................................................................. 569 Removal.................................................................................... 569 Installation............................................................................... 570 Disassembly................................................................................ 571 Cleaning and Inspection.................................................................... 571 Assembly................................................................................... 573 BRAKE LINING................................................................................... 573 Replacement................................................................................ 573 FRONT SERVICE BRAKE BURNISHING................................................................. 575 BRAKE BLEEDING PROCEDURE................................................................... 576 REAR BRAKES INDEX...................................................................................... 577 REAR DISC BRAKES................................................................................... 579 REAR BRAKES.................................................................................... 579 CALIPER, DISC, AND PARKING BRAKE............................................................... 579 Removal.................................................................................... 579 Installation............................................................................... 580 CALIPER PISTON................................................................................. 582 Piston Assembly Removal.................................................................... 582 Inspection................................................................................. 582 Piston Assembly Installation............................................................... 583 FUNCTIONAL TEST OF PISTON ASSEMBLY............................................................. 584 Return Spring Force........................................................................ 584 Built-In Clearance......................................................................... 584 Grip Force................................................................................. 586 Grip Force Measurement..................................................................... 587 Spring Force Measurement................................................................... 589 Disassembly of Piston Assembly............................................................. 590 Assembly of Piston Assembly................................................................ 591 BENCH TEST..................................................................................... 591 BRAKE LINING................................................................................... 592 Replacement................................................................................ 592 SERVICE BRAKE BURNISHING....................................................................... 595 SAFETY PRECAUTIONS......................................................................... 595 Rear Brake Burnishing.................................................................. 596 BRAKE BLEEDING PROCEDURE................................................................... 597 Spring Force Measurement............................................................... 598 PARKING BRAKE INDEX.................................................................................... 599 PARKING BRAKE...................................................................................... 601 GENERAL INFORMATION............................................................................ 601 PARKING BRAKE CALIPER.......................................................................... 601 Lining Thickness Inspection................................................................ 601 Removal.................................................................................... 602 Installation............................................................................... 602 Parking Brake Adjustment................................................................... 603 Parking Brake Caliper Disassembly.......................................................... 604 Cleaning and Inspection.................................................................... 605 Parking Brake Caliper Assembly............................................................. 606 PARKING BRAKE LINING REPLACEMENT............................................................... 606 PARKING BRAKE BURNISH PROCEDURE................................................................ 606 Lining Conditioning........................................................................ 606 BRAKE BLEEDING PROCEDURE....................................................................... 607 SECTION L HYDRAULIC SYSTEM................................................................................. 609 HYDRAULIC SYSTEM OVERVIEW INDEX ....................................................................... 611 HYDRAULIC SYSTEM OVERVIEW.......................................................................... 612 Hoist Circuit Operation........................................................................ 612 Steering, Brake and Pantograph Circuit Operation............................................... 612 Axle Blower System Operation................................................................... 612 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX ............................................................... 615 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................................. 617 HOIST PUMP..................................................................................... 617 Removal.................................................................................... 617 Installation............................................................................... 619 Disassembly................................................................................ 619 Inspection................................................................................. 622 Assembly................................................................................... 623 PISTON PUMP................................................................................ 628 Removal................................................................................ 628 Installation........................................................................... 629 Disassembly............................................................................ 631 Inspection of Parts.................................................................... 637 Assembly............................................................................... 639 AXLE BLOWER HYDRAULIC MOTOR........................................................................ 644 Removal........................................................................................ 644 Installation................................................................................... 644 Rear Axle Blower Housing....................................................................... 644 Disassembly................................................................................ 644 Assembly................................................................................... 645 Disassembly................................................................................ 647 Inspection................................................................................. 649 Assembly................................................................................... 650 Trouble Shooting........................................................................... 651 Hand Wheel Control............................................................................. 652 Disassembly................................................................................ 652 Assembly................................................................................... 652 HYDRAULIC TANK................................................................................. 654 Filling Instructions....................................................................... 654 Removal.................................................................................... 655 Installation............................................................................... 655 HYDRAULIC TANK STRAINER AND DIFFUSER........................................................... 656 Removal.................................................................................... 656 Inspect and Clean.......................................................................... 657 Installation............................................................................... 657 STEERING CIRCUIT INDEX................................................................................ 659 STEERING CIRCUIT................................................................................... 661 STEERING CIRCUIT OPERATION..................................................................... 661 COMPONENT DESCRIPTION.......................................................................... 662 Steering Control Valve..................................................................... 662 Unloader Valve............................................................................. 663 Bleed-Down Manifold Valve.................................................................. 663 Flow Amplifier............................................................................. 668 FLOW AMPLIFIER SYSTEM OPERATION................................................................ 669 No Steer................................................................................... 669 Steering Left.............................................................................. 671 Steering Right............................................................................. 673 No Steer, External Shock Load.............................................................. 675 Steering Pump.............................................................................. 677 High Pressure Filter....................................................................... 677 Accumulators............................................................................... 677 Low Precharge Warning Switch............................................................... 677 STEERING CONTROL VALVE INDEX .......................................................................... 679 STEERING CONTROL VALVE............................................................................. 681 Removal........................................................................................ 681 Installation................................................................................... 682 STEERING CONTROL VALVE REBUILD................................................................. 683 Disassembly................................................................................ 683 Cleaning and Inspection.................................................................... 684 Assembly................................................................................... 684 BRAKE / STEERING PUMP.......................................................................... 688 Removal.................................................................................... 688 Installation............................................................................... 690 Disassembly................................................................................ 691 Inspection of Parts........................................................................ 691 Assembly................................................................................... 693 STEERING CIRCUIT COMPONENT REPAIR INDEX................................................................ 695 STEERING CIRCUIT COMPONENT REPAIR.................................................................. 697 BLEED-DOWN MANIFOLD............................................................................ 697 Removal.................................................................................... 697 Installation............................................................................... 697 ACCUMULATOR.................................................................................... 698 Removal.................................................................................... 698 Installation............................................................................... 699 Disassembly................................................................................ 700 Cleaning and Inspection.................................................................... 700 Assembly................................................................................... 701 Leak Testing............................................................................... 702 STEERING ACCUMULATOR CHARGING.................................................................. 703 Temperature During Precharge............................................................... 706 ACCUMULATOR STORAGE............................................................................ 707 Installation............................................................................... 707 FLOW AMPLIFIER................................................................................. 708 Removal.................................................................................... 708 Installation............................................................................... 708 Disassembly................................................................................ 709 Assembly................................................................................... 712 STEERING CYLINDERS............................................................................. 713 Disassembly................................................................................ 713 Piston Seal and Bearing Installation....................................................... 713 Cylinder Assembly.......................................................................... 713 Test....................................................................................... 713 TROUBLESHOOTING CHART.............................................................................. 716 HOIST CIRCUIT INDEX.................................................................................... 721 HOIST CIRCUIT...................................................................................... 723 HOIST CIRCUIT OPERATION........................................................................ 723 COMPONENT DESCRIPTION.......................................................................... 724 Hydraulic Tank............................................................................. 724 Hydraulic Pump............................................................................. 724 High Pressure Filter....................................................................... 724 Hoist Valve................................................................................ 724 Hoist Pilot Valve.......................................................................... 725 Bleed-Down Manifold........................................................................ 726 Counterbalance Manifold.................................................................... 726 Hoist-Up Limit Solenoid.................................................................... 726 Pilot Operated Check Valve................................................................. 726 HOIST VALVE OPERATION.......................................................................... 728 Float Operation............................................................................ 728 Power Up Operation (Figure 7-6)............................................................ 730 Hold Operation (Figure 7-7)................................................................ 732 Power Down Operation (Figure 7-8).......................................................... 734 Float Operation (Figure 7-9)............................................................... 736 HOIST CIRCUIT COMPONENT REPAIR INDEX................................................................... 739 HOIST CIRCUIT COMPONENT REPAIR..................................................................... 741 HOIST VALVE.................................................................................... 741 Removal.................................................................................... 741 Installation............................................................................... 741 O-Ring Replacement......................................................................... 743 INLET SECTION.................................................................................. 744 Disassembly................................................................................ 744 Cleaning and Inspection.................................................................... 745 Assembly................................................................................... 745 REAR SPOOL SECTION (WORK PORTS)................................................................ 746 Disassembly................................................................................ 746 Cleaning and Inspection.................................................................... 748 Assembly................................................................................... 748 HOIST PILOT VALVE.............................................................................. 750 Removal.................................................................................... 750 Installation............................................................................... 750 Disassembly................................................................................ 751 Cleaning and Inspection.................................................................... 752 Assembly................................................................................... 752 HOIST UP LIMIT SOLENOID VALVE.................................................................. 753 HOIST CYLINDERS................................................................................ 754 Removal.................................................................................... 754 Installation............................................................................... 755 Disassembly................................................................................ 757 Cleaning and Inspection.................................................................... 758 SS1143 Tightening Tool - Assembly Drawing.................................................. 759 ASSEMBLY OF QUILL AND CYLINDER................................................................. 759 Quill Installation......................................................................... 759 Installation Of Check Balls And Plugs In Quill............................................. 760 Assembly of Cylinder....................................................................... 762 COUNTERBALANCE MANIFOLD........................................................................ 763 HIGH PRESSURE FILTERS INDEX............................................................................ 765 HYDRAULIC SYSTEM FILTERS........................................................................... 767 HOIST CIRCUIT FILTER........................................................................... 767 Filter Element Replacement................................................................. 767 Removal.................................................................................... 768 Installation............................................................................... 768 Indicator Switch........................................................................... 768 STEERING CIRCUIT FILTER........................................................................ 769 Filter Element Replacement................................................................. 769 Removal.................................................................................... 770 Installation............................................................................... 770 Indicator Switch........................................................................... 770 INDICATOR SWITCH............................................................................... 770 Test Procedure............................................................................. 770 HYDRAULIC CHECK-OUT PROCEDURE INDEX.................................................................... 773 HYDRAULIC CHECK-OUT PROCEDURE...................................................................... 775 INITIAL START UP AND FLUSHING.................................................................. 775 COMPONENT CHECKOUT AND ADJUSTMENT.............................................................. 777 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE.................................. 779 Counterbalance Valve Adjustment............................................................ 781 Manifold Assembly.......................................................................... 781 OIL CLEANLINESS CHECK.......................................................................... 781 Oil Sampling Location On Truck............................................................. 781 Oil Sampling Process and Cleanliness Criteria.............................................. 782 DISABLED TRUCK DUMPING PROCEDURE............................................................... 782 Hookup..................................................................................... 782 Raising the Body........................................................................... 782 Lowering the Body.......................................................................... 783 TROUBLESHOOTING CHART.......................................................................... 784 Hoist Pump................................................................................. 784 Steering Circuit........................................................................... 786 Brake/Steering Pump........................................................................ 788 Flow Amplifier - Refer to Figure 10-9...................................................... 790 SECTION M OPTIONS AND SPECIAL TOOLS ....................................................................... 791 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM INDEX ........................................................ 793 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM........................................................... 795 SYSTEM ADJUSTMENT.............................................................................. 795 PUMP........................................................................................... 798 Removal........................................................................................ 798 Disassembly.................................................................................... 798 Inspection..................................................................................... 798 Assembly....................................................................................... 798 Installation................................................................................... 798 BLOWER DRIVE MOTOR............................................................................. 801 Removal........................................................................................ 801 Disassembly.................................................................................... 801 Inspection Of Parts............................................................................ 802 Assembly....................................................................................... 803 Installation................................................................................... 804 BLOWER BEARING REPAIR.......................................................................... 804 Removal.................................................................................... 804 Replacement................................................................................ 804 Assembly................................................................................... 805 AIR CLEANER.................................................................................... 805 Assembly................................................................................... 805 Removal.................................................................................... 805 Assembly................................................................................... 805 SECTION M7 HEATER OPTIONS INDEX........................................................................ 807 ENGINE OIL HEATERS................................................................................. 809 GENERAL INFORMATION............................................................................ 809 TROUBLESHOOTING................................................................................ 809 HEATER ELEMENT................................................................................. 809 Removal.................................................................................... 809 Installation............................................................................... 810 ENGINE COOLANT HEATER.............................................................................. 811 GENERAL........................................................................................ 811 Maintenance................................................................................ 811 HEATING ELEMENT................................................................................ 811 Removal.................................................................................... 811 Installation............................................................................... 812 THERMOSTAT..................................................................................... 812 Removal.................................................................................... 812 Installation............................................................................... 812 HYDRAULIC OIL HEATERS.............................................................................. 813 GENERAL INFORMATION............................................................................ 813 TROUBLESHOOTING................................................................................ 813 HEATER ELEMENT................................................................................. 813 Removal.................................................................................... 813 Installation............................................................................... 814 SECTION M8 SPECIAL TOOLS INDEX......................................................................... 815 SPECIAL TOOLS...................................................................................... 817 SEAL INSTALLATION RING......................................................................... 821 HYDRAULIC SYSTEM VACUUM PUMP................................................................... 822 SECTION M19 RADIATOR SHUTTERS INDEX .................................................................. 825 RADIATOR SHUTTERS.................................................................................. 827 OPERATION...................................................................................... 827 Hydraulic Circuit.......................................................................... 827 Electrical Circuit:........................................................................ 828 MAINTENANCE AND REPAIR......................................................................... 828 TROUBLESHOOTING................................................................................ 829 Hydraulic Troubleshooting.................................................................. 832 Electrical Troubleshooting................................................................. 834 SECTION N OPERATOR'S CAB................................................................................... 835 TRUCK CAB INDEX ....................................................................................... 837 TRUCK CAB.......................................................................................... 839 Description.................................................................................... 839 Removal........................................................................................ 840 Installation................................................................................... 842 CAB DOOR........................................................................................... 842 Removal........................................................................................ 842 Installation................................................................................... 843 Door Adjustment................................................................................ 843 Door Jam Bolt Adjustment....................................................................... 843 Door Handle Plunger Adjustment................................................................. 845 Replace Door Glass............................................................................. 846 Replace Door Window Regulator.................................................................. 850 Replace Door Handle or Latch Assembly.......................................................... 850 Door and Door Hinge Seal Replacement........................................................... 851 Door Opening Seal Removal...................................................................... 851 Installation................................................................................... 851 GLASS REPLACEMENT.................................................................................. 852 Adhesive-Bonded Windows........................................................................ 852 Recommended Tools/Supplies..................................................................... 852 Replacement Procedure.......................................................................... 852 Windshield and Rear Glass...................................................................... 853 Removal........................................................................................ 853 Installation................................................................................... 854 Removal and Installation of Operator Seat.......................................................... 855 Inspection..................................................................................... 855 Removal........................................................................................ 855 Installation................................................................................... 855 Removal and Installation of Passenger Seat......................................................... 856 Removal........................................................................................ 856 Installation................................................................................... 856 CAB COMPONENTS INDEX................................................................................... 857 CAB COMPONENTS..................................................................................... 859 WINDSHIELD WIPERS.............................................................................. 859 WIPER MOTOR REPLACEMENT.................................................................... 859 Removal................................................................................ 859 Installation........................................................................... 859 WIPER ARM REPLACEMENT...................................................................... 859 Removal................................................................................ 859 Installation........................................................................... 860 WIPER LINKAGE REPLACEMENT.................................................................. 860 Removal................................................................................ 860 Installation........................................................................... 861 WINDSHIELD WASHER.......................................................................... 861 Operation.............................................................................. 861 Service................................................................................ 861 OPERATOR COMFORT INDEX ................................................................................ 863 OPERATOR COMFORT................................................................................... 865 HEATER / AIR CONDITIONER....................................................................... 865 Fan Speed Control Knob..................................................................... 865 Temperature Control Knob................................................................... 865 Air Flow Directional Knob.................................................................. 865 Heater/Air Conditioner Vents............................................................... 866 COMPONENTS..................................................................................... 866 Fuse and Circuit Breaker................................................................... 866 Relays..................................................................................... 866 Heater Core................................................................................ 866 Fan Motor And Speed Control................................................................ 867 Actuators.................................................................................. 867 Cab Air Filter............................................................................. 867 ENVIRONMENTAL IMPACT OF AIR CONDITIONING....................................................... 870 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES...................................................... 870 PRINCIPLES OF REFRIGERATION.................................................................... 870 Air Conditioning........................................................................... 870 Refrigeration - The Act Of Cooling......................................................... 871 The Refrigeration Cycle.................................................................... 871 AIR CONDITIONER SYSTEM COMPONENTS.............................................................. 872 Compressor (Refrigerant Pump).............................................................. 872 Service Valves............................................................................. 872 Condenser.................................................................................. 872 Receiver-Drier............................................................................. 872 Expansion Block Valve...................................................................... 873 Accumulator................................................................................ 873 Evaporator................................................................................. 873 ELECTRICAL CIRCUIT............................................................................. 874 Thermostat................................................................................. 874 Compressor Clutch.......................................................................... 874 Trinary™ Switch............................................................................ 875 SYSTEM SERVICING............................................................................... 876 SERVICE TOOLS AND EQUIPMENT.................................................................... 877 Recovery/Recycle Station................................................................... 877 Leak Detector.............................................................................. 877 Service Valves............................................................................. 878 Vacuum Pump................................................................................ 878 Manifold Gauge Set......................................................................... 879 Installing Manifold Gauge Set.............................................................. 880 Purging Air From Service Hoses............................................................. 880 SYSTEM PERFORMANCE TEST........................................................................ 881 SYSTEM OIL..................................................................................... 882 Handling and Reusing PAG Oil............................................................... 882 Oil Quantity............................................................................... 882 Checking System Oil........................................................................ 882 REFRIGERANT.................................................................................... 883 Recycled Refrigerant....................................................................... 883 Reclaimed Refrigerant...................................................................... 883 Refrigerant Quantity....................................................................... 883 R-134a Refrigerant Containers.............................................................. 884 SYSTEM LEAK TESTING............................................................................ 884 Electronic Leak Detector................................................................... 885 Tracer Dyes................................................................................ 885 Soap and Water............................................................................. 885 RECOVERING AND RECYCLING THE REFRIGERANT....................................................... 885 Draining Oil from the Previous Recovery Cycle.............................................. 885 Performing the Recovery Cycle.............................................................. 885 Performing the Recycling Procedure......................................................... 886 Evacuating and Charging the A/C System..................................................... 886 SYSTEM REPAIR.................................................................................. 886 System Flushing............................................................................ 886 A/C DRIVE BELT CHECKOUT PROCEDURE.............................................................. 887 Pulley Alignment........................................................................... 887 Belt Tension Check......................................................................... 887 COMPONENT REPLACEMENT.......................................................................... 889 Hoses and Fittings......................................................................... 889 Lines...................................................................................... 889 Expansion Valve............................................................................ 889 Receiver-Drier............................................................................. 889 Thermostat................................................................................. 889 Compressor................................................................................. 890 Accumulator................................................................................ 890 Clutch..................................................................................... 890 Servicing the Compressor Clutch............................................................ 891 Pulley Removal............................................................................. 893 Clutch Coil Check.......................................................................... 894 Pulley Installation........................................................................ 894 Clutch Assembly Installation............................................................... 894 EVACUATING THE SYSTEM.......................................................................... 896 CHARGING THE A/C SYSTEM........................................................................ 898 TROUBLESHOOTING.................................................................................... 899 Preliminary Checks............................................................................. 899 Diagnosis Of Gauge Readings And System Performance............................................. 899 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS..................................................... 900 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................................... 906 OPERATOR CONTROLS AND EQUIPMENT INDEX.................................................................. 907 OPERATOR CAB AND CONTROLS.......................................................................... 909 STEERING WHEEL AND CONTROLS.................................................................... 910 HORN BUTTON................................................................................ 910 TILT/TELESCOPE LEVER....................................................................... 910 M ULTI-FUNCTION TURN SIGNAL SWITCH......................................................... 910 Turn Signal Operation.................................................................. 910 High Beam Headlight Operation.......................................................... 910 Windshield Wiper Operation............................................................. 910 STEERING COLUMN............................................................................ 911 Removal................................................................................ 911 Inspection............................................................................. 911 Installation........................................................................... 912 STEERING WHEEL............................................................................. 912 Removal................................................................................ 912 Installation........................................................................... 912 PEDALS......................................................................................... 914 SERVICE BRAKE PEDAL........................................................................ 914 DYNAMIC RETARDER PEDAL..................................................................... 914 Optional - Dual Function/Single Pedal.................................................. 914 THROTTLE PEDAL............................................................................. 914 GRADE/SPEED WARNING CHART.................................................................. 915 OVERHEAD PANEL CONTROLS AND COMPONENTS......................................................... 915 RADIO SPEAKERS............................................................................. 915 WARNING ALARM BUZZER....................................................................... 915 CAB RADIO.................................................................................. 915 WARNING LIGHTS DIMMER CONTROL.............................................................. 915 WARNING/STATUS INDICATOR LIGHT PANEL....................................................... 915 AIR CLEANER VACUUM GAUGES.................................................................. 915 WINDSHIELD WIPERS.......................................................................... 915 CENTER CONSOLE................................................................................. 916 TRUCK CONTROLS............................................................................. 916 F-N-R Selector Switch.................................................................. 916 Hoist Control Lever.................................................................... 917 CONSOLE SWITCHES AND CONTROLS.............................................................. 917 Ashtray................................................................................ 917 Cigarette Lighter...................................................................... 917 Left-Hand Window Control Switch........................................................ 917 Right-Hand Window Control Switch....................................................... 917 Engine Shutdown Switch................................................................. 917 Override Switch........................................................................ 917 Retard Speed Control (RSC) Switch...................................................... 918 Retard Speed Control (RSC) Dial........................................................ 918 Statex III Download Port............................................................... 919 Engine Diagnostic Port (CENSE)......................................................... 919 Modular Mining Port.................................................................... 919 Passenger Seat......................................................................... 919 Engine Diagnostic Connectors........................................................... 919 Engine Diagnostics Connector........................................................... 919 Data Store Button...................................................................... 919 PAYLOAD METER.............................................................................. 919 Payload Meter Download Connector....................................................... 919 OPERATOR’S SEAT................................................................................ 920 Seat Belts................................................................................. 920 Adjustment................................................................................. 920 INSTRUMENT PANEL............................................................................... 921 CONTROL SYMBOLS............................................................................ 921 CONTROL SWITCHES AND GAUGES................................................................ 922 Key Switch............................................................................. 922 Engine Shutdown Switch With Timer Delay................................................ 923 Fog Light Switch....................................................................... 923 Ladder Light Switch.................................................................... 923 Backup Light Switch.................................................................... 923 Panel Illumination Lights.............................................................. 923 Cab Air Conditioner/Heater Vents....................................................... 923 Engine Cold Weather Starting Aid Switch................................................ 923 Rotating Beacon Light Switch........................................................... 923 Heated Mirror Switch................................................................... 923 Wheel Brake Lock Switch................................................................ 924 Parking Brake Switch................................................................... 924 Digital Tachometer..................................................................... 924 Right Turn Signal Indicator Light...................................................... 925 High Beam Headlight Indicator Light.................................................... 925 Left Turn Signal Indicator Light....................................................... 925 Digital Speedometer/Payload Meter Display.............................................. 925 Voltmeter Gauge........................................................................ 925 Engine Oil Pressure Gauge.............................................................. 925 Engine Water Temperature Gauge......................................................... 925 Fuel Gauge............................................................................. 925 Engine Hourmeter....................................................................... 925 Headlight Switch....................................................................... 926 Panel Illumination Lights Dimmer Rheostat.............................................. 926 Payload Meter Switch................................................................... 926 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL.................................................. 927 DESCRIPTION OF INDICATOR SYMBOLS........................................................... 927 INDICATOR LIGHT FUNCTIONS.................................................................. 928 A1. High Hydraulic Oil Temperature..................................................... 928 B1. Low Steering Pressure.............................................................. 928 C1. Low Accumulator Precharge Pressure................................................. 929 D1. Electric System Fault.............................................................. 929 E1. Low Brake Pressure................................................................. 929 A2. Low Hydraulic Tank Level........................................................... 929 B2. Automatic Lubrication System Pressure.............................................. 929 C2. Circuit Breaker Tripped............................................................ 929 D2. Hydraulic Oil Filter Monitor....................................................... 930 E2. Low Fuel........................................................................... 930 A3. Parking Brake...................................................................... 930 B3. Service Brake...................................................................... 930 C3. Body Up............................................................................ 930 D3. Dynamic Retarding.................................................................. 930 E3. Stop Engine........................................................................ 930 A4. Not Used........................................................................... 931 B4. Manual Backup Lights............................................................... 931 C4. Engine Shutdown Timer.............................................................. 931 D4. Retard Speed Control (RSC)......................................................... 931 E4. Check Engine....................................................................... 931 A5. Service Engine Indicator (AEM)..................................................... 931 B5. High Wheel Motor Temperature....................................................... 931 C5. Blower Fault....................................................................... 931 D5, E5, A6, B6, and C6. Not Used....................................................... 931 D6. Service Engine (CENSE)............................................................. 931 E6. Not Used........................................................................... 931 Komatsu Engines w/Centry™ Fuel Control................................................. 932 Hazard Warning Light Switch............................................................ 932 Lamp Test Switch/Centry™ Diagnostic Test Switch........................................ 932 TROLLEY INDICATOR LIGHTS................................................................... 932 A7. Diesel Power Indicator............................................................. 932 B7. Ready For Trolley Indicator........................................................ 932 C7. On Trolley Indicator............................................................... 932 D7. Trolley Fault Indicator............................................................ 933 E7. Left Limit Indicator (Optional).................................................... 933 A8. Max Speed Indicator................................................................ 933 B8. High Speed Indicator............................................................... 933 C8. Med Speed Indicator................................................................ 934 D8. Low Speed Indicator................................................................ 934 E8. Right Limit Indicator (Optional)................................................... 934 REAR AXLE LIGHT BAR............................................................................ 935 Backup Lights.............................................................................. 935 Retard Lights.............................................................................. 935 Brake Light................................................................................ 935 Backup Alarm............................................................................... 935 CENTRY™ FUEL SYSTEM DIAGNOSTICS................................................................ 936 GENERAL OPERATION.......................................................................... 936 DETERMINING FAULT CODES.................................................................... 936 EXITING THE DIAGNOSTICS MODE............................................................... 937 SECTION P LUBRICATION AND SERVICE ......................................................................... 939 LUBRICATION AND SERVICE INDEX.......................................................................... 941 LUBRICATION AND SERVICE............................................................................ 943 GENERAL INFORMATION............................................................................ 943 HYDRAULIC TANK SERVICE......................................................................... 943 Adding Oil................................................................................. 943 COOLANT LEVEL CHECK............................................................................ 944 Radiator Filling Procedure................................................................. 944 Coolant Specifications..................................................................... 944 Unacceptable Practices..................................................................... 944 WHEEL MOTOR SERVICE............................................................................ 944 RESERVE ENGINE OIL SYSTEM (Optional)........................................................... 945 Reserve Oil Tank Filling Procedure (Remote fill)........................................... 945 Inline Screen.............................................................................. 945 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS.................................................... 947 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)........................................ 948 50 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................................... 949 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................... 949 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................... 950 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)........................................ 951 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................... 952 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)........................................ 953 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 954 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 955 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 955 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 956 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................. 957 AUTOMATIC LUBRICATION SYSTEM INDEX..................................................................... 959 AUTOMATIC LUBRICATION SYSTEM....................................................................... 961 GENERAL DESCRIPTION............................................................................ 961 SYSTEM COMPONENTS.............................................................................. 962 Filter Assembly............................................................................ 962 Hydraulic Motor and Grease Pump............................................................ 962 Reservoir.................................................................................. 962 Fixed Pressure Reducing Valve.............................................................. 962 Flow Control Valve......................................................................... 962 Solenoid Valve............................................................................. 963 Vent Valve................................................................................. 963 24VDC Lubrication Cycle Timer.............................................................. 963 Time Delay Module.......................................................................... 963 Pump Cutoff Pressure Switch................................................................ 963 Unloader Valve............................................................................. 963 Pressure Switch............................................................................ 963 Manual Override Button..................................................................... 963 Injectors.................................................................................. 963 SYSTEM OPERATION............................................................................... 966 Normal Operation........................................................................... 966 Pressure Failure Detection Circuits........................................................ 967 GENERAL INSTRUCTIONS........................................................................... 968 LUBRICANT REQUIRED FOR SYSTEM.............................................................. 968 SYSTEM PRIMING............................................................................. 968 LUBRICANT PUMP............................................................................. 969 Pump Housing Oil Level................................................................. 969 Pump Pressure Control.................................................................. 969 FILTER AND RESERVOIR....................................................................... 969 Filter Assembly Element................................................................ 970 INJECTORS (SL-1 Series H).................................................................. 970 Injector Specifications................................................................ 970 Injector Adjustment.................................................................... 970 INJECTOR OPERATION................................................................................. 972 SYSTEM CHECKOUT................................................................................ 973 Lubrication Cycle Timer Check.............................................................. 973 Lubrication Cycle Timer Adjustment......................................................... 974 PREVENTIVE MAINTENANCE INSPECTION.............................................................. 974 10 Hour Lubrication System Inspection...................................................... 974 100 Hour Inspection........................................................................ 974 250 Hour Inspection........................................................................ 974 500 Hour Inspection........................................................................ 975 1000 Hour Inspection....................................................................... 975 PUMP REBUILD................................................................................... 976 Disassembly................................................................................ 976 Cleaning and Inspection.................................................................... 976 Assembly................................................................................... 978 VENT VALVE REBUILD............................................................................. 979 Disassembly and Assembly................................................................... 979 SYSTEM TROUBLESHOOTING CHART................................................................... 980 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX ............................................................ 983 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 985 AXLE BOX....................................................................................... 985 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 986 ARMATURE AREA.................................................................................. 986 AT TIRE CHANGE................................................................................. 986 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 987 GENERATOR/ALTERNATOR........................................................................... 987 GRID BLOWER MOTOR.............................................................................. 987 CONTROL EQUIPMENT CHECKS....................................................................... 987 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 988 VEHICLE OPERATIONS TESTS....................................................................... 988 SECTION R SYSTEM SCHEMATICS................................................................................ 989 EF5755 HYDRAULIC BRAKE SYSTEM SCHEMATIC ............................................................... 990 EM1369 HYDRAULIC SYSTEM SCHEMATIC ..................................................................... 991 XS1000 ELECTRICAL SCHEMATIC............................................................................ 992 HE484 HVAC ELECTRICAL SCHEMATIC .......................................................................1026
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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