Komatsu 730E Trolley Dump Truck Shop Manual CEBM016301 PDF

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Komatsu 730E Trolley Dump Truck Shop Manual CEBM016301 – PDF DOWNLOAD

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Komatsu 730E Trolley Dump Truck Shop Manual CEBM016301 – PDF DOWNLOAD 

Language : English
Pages : 1090
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 730E Trolley Dump Truck Shop Manual CEBM016301 – PDF DOWNLOAD

SERIAL NUMBERS A30355, A30392, A30393, A30403 & A30406

• This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
• All operators and maintenance personnel must understand the content in this manual before maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before repairing the truck.
• This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to right, left, front, or rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lbs). All torque specifications have ±10% tolerance
  unless otherwise specified.
• The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
• A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW) rating.
• The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design
  and application guidelines are sensitive to the total maximum GVW. GVW is the total truck weight. This is equal to the empty vehicle weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty truck. This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 730E Trolley Dump Truck Shop Manual CEBM016301 – PDF DOWNLOAD 

SERIAL NUMBERS A30355, A30392, A30393, A30403 & A30406

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
SECTION A2 MAJOR COMPONENT DESCRIPTION 11
SPECIFICATIONS 13
Komatsu SSA16V159 13
SECTION A3 GENERAL SAFETY AND OPERATION 15
GENERAL SAFETY 17
PERSONAL SAFETY 17
Safety Rules 17
Truck Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 18
Fire Extinguishers And First Aid Kits 18
Precautions For High Temperature Fluids 18
Asbestos Dust Hazard Prevention 18
Fire Prevention For Fuel And Oil 19
ROPS Precautions 19
Preventing Injury From Work Equipment 19
Precautions For Optional Attachments 19
Precautions When Starting The Machine 19
PRECAUTIONS FOR TRUCK OPERATION 20
Safety Is Thinking Ahead 20
Safety At The Work Site 20
Fire Prevention 20
Preparing For Operation 20
Ventilation For Enclosed Areas 20
Mirrors, Windows, And Lights 21
In The Operator’s Cab – Before Starting The Engine 21
OPERATING THE MACHINE 21
Starting The Engine 21
Truck Operation – General 21
Traveling In The Truck 22
Precautions When Traveling In Reverse 22
Traveling On Slopes 23
Ensuring Good Visibility 23
Operating On Snow 23
Avoid Damage To The Dump Body 23
Driving Near High-Voltage Cables 23
When Loading The Truck 24
When Dumping 24
Working On Loose Ground 24
Parking The Machine 24
TOWING 24
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump-Starting With Booster Cables 25
MAINTENANCE PRECAUTIONS 25
BEFORE PERFORMING MAINTENANCE 25
Stopping The Engine Before Service 25
Warning Tag 26
Proper Tools 26
Securing The Dump Body 26
DURING MAINTENANCE 27
Personnel 27
Attachments 27
Working Under The Machine 27
Keeping The Machine Clean 27
Adding Fuel Or Oil 27
Radiator Coolant Level 27
Use Of Lighting 27
Precautions With The Battery 28
Handling High-Pressure Hoses 28
Precautions With High-Pressure Oil 28
Maintenance Near High Temperatures And High Pressures 28
Rotating Fan And Belts 28
Waste Materials 28
Use of Safety Tie-Off Anchor During Maintenance and Repair 28
TIRES 29
Handling Tires 29
Tire Maintenance 29
Storing Tires After Removal 30
ADDITIONAL JOB SITE RULES 31
WHEN REPAIRS ARE NECESSARY 32
OPERATING INSTRUCTIONS 33
PREPARING FOR OPERATION 33
SAFETY IS THINKING AHEAD 33
WALK-AROUND INSPECTION 33
ENGINE START-UP 37
AFTER THE ENGINE HAS STARTED 38
MACHINE OPERATION SAFETY PRECAUTIONS 39
LOADING 39
HAULING 40
PASSING 40
DUMPING 41
To Raise The Dump Body: 41
To Lower The Dump Body: (When dumping over a berm or into a crusher): 42
To Lower The Dump Body (When dumping on flat ground): 42
TOWING 43
SAFE PARKING PROCEDURES 43
ENGINE SHUTDOWN PROCEDURE 44
DELAYED ENGINE SHUTDOWN PROCEDURE 44
SUDDEN LOSS OF POWER 45
EMERGENCY STEERING SYSTEM 45
Operation 45
Testing 46
TROLLEY OPERATING INSTRUCTIONS 46
AFTER THE ENGINE HAS STARTED 46
OPERATING IN DIESEL MODE 47
OPERATING IN TROLLEY LINE MODE 47
GETTING ON LINE 48
Operating On Trolley 50
GETTING OFF LINE 51
LINE STATUS SIGNALS 51
LINE STATUS SIGNAL MARKINGS 52
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION 52
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK 53
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS 53
TRUCK FAILURE WHILE ON TROLLEY 53
SECTION A4 WARNINGS AND CAUTIONS 55
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 63
SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX 73
SHORT TERM IDLE PERIODS 75
PREPARATION FOR STORAGE 76
REMOVAL FROM STORAGE 77
RECONDITIONING AN IDLE VEHICLE 78
ENGINE OPERATION 81
After The Engine Has Started 81
ENGINE STORAGE 82
Temporary Storage (30 Days Or Less) 82
Extended Storage (More Than 30 Days) 83
RESTORING AN ENGINE AFTER EXTENDED STORAGE 84
ELECTRIC DRIVE TRUCKS 85
Storing A Truck That Is Operational 85
Storing A Truck That Is Not Operational 86
Storing A Major Component 87
Periodic Inspections 87
Placing Equipment Into Service After Storage 87
SECTION B STRUCTURES INDEX 89
SECTION B2 STRUCTURAL COMPONENTS INDEX 91
STRUCTURAL COMPONENTS 93
LADDERS 93
Removal 93
Installation 93
GRILLE AND HOOD 94
Removal 94
Installation 94
RIGHT-HAND DECK 94
Removal 94
Installation 96
CENTER DECK 96
LEFT-HAND DECK 97
Removal 97
Installation 97
SECTION B3 DUMP BODY INDEX 99
DUMP BODY 101
Removal 101
Installation 102
BODY SLING 102
BODY PADS 103
BODY GUIDE 103
Adjustment 103
BODY POSITION INDICATOR 104
HOIST LIMIT SWITCH 104
ROCK EJECTORS 104
Inspection 104
SECTION B4 FUEL TANK INDEX 105
FUEL TANK 107
Removal 107
Repair 107
Cleaning 107
Installation 108
FUEL GAUGE SENDER 109
Removal 109
Installation 109
LOW FUEL SENDER 110
Removal 110
Installation 110
TANK BREATHER VALVE 111
Removal 111
Installation 111
Disassembly 111
Assembly 111
FUEL RECEIVER (WIGGINS QUICK FILL) 112
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL) 113
SECTION C ENGINE INDEX 115
SECTION C2 POWER MODULE INDEX 117
POWER MODULE 119
GENERAL INFORMATION 119
POWER MODULE SERVICE 120
Removal 120
Installation 124
SECTION C3 COOLING SYSTEM INDEX 127
COOLING SYSTEM 129
RADIATOR 129
Removal 129
Service 130
Installation 130
RADIATOR FILL PROCEDURE 131
RADIATOR REPAIR 131
Internal Inspection 131
External Cleaning 132
Disassembly 132
Cleaning and Inspection 133
Assembly 133
Additional Service Information 135
PRESSURE TESTING 135
COOLANT SYSTEM TROUBLESHOOTING 135
SECTION C4 POWER TRAIN INDEX 137
POWER TRAIN 139
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 139
General Information 139
Removal 139
ALTERNATOR INSTALLATION 141
Engine/Alternator Mating 141
Alternator Measurement 141
Engine End Play Measurement 142
Determining Shim Requirements 143
Installing Alternator On Engine 144
ENGINE 145
Removal 145
Installation 145
SECTION C5 AIR CLEANERS INDEX 147
AIR CLEANERS 149
Service Checks 149
Filter Element Replacement 150
Main Filter Element Cleaning 152
Precleaner Section 153
Cleaning Precleaner Tubes 153
Air Intake Troubleshooting 154
SECTION C7 FAN DRIVE CLUTCH INDEX 155
COMPONENTS 156
Input 156
Output 156
Stationary Components 157
OPERATIONAL MODES 158
Fully Engaged 158
Modulated Variable Speed 158
Fully Released 159
Lubricating and Cooling Oil 160
MAINTENANCE 161
TROUBLESHOOTING 162
Preliminary Checks 162
FIELD CHECK DIAGNOSIS 163
Preliminary Checks – Engine Off 163
Check Clutch Release 163
Check Clutch Lock-up 164
Overheating 164
Thermal Sensor and Solenoid Valve 165
On Truck Test 165
Off Truck Test 165
FAN CLUTCH DISASSEMBLY INSTRUCTIONS 170
REASSEMBLY OF THE FAN CLUTCH 177
INSPECTION OF PARTS 188
REBUILD TOOLS 192
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 193
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 195
ELECTRICAL SYSTEM DESCRIPTION 197
BATTERIES 197
Maintenance and Service 197
Troubleshooting 197
BATTERY CHARGING ALTERNATOR 199
24VDC ELECTRIC START SYSTEM 199
CRANKING MOTORS 199
Removal 199
Installation 200
CRANKING MOTOR TROUBLESHOOTING 200
Preliminary Inspection 201
No-Load Test 201
Interpreting Results of Tests 201
Disassembly 202
Cleaning and Inspection 202
Armature Servicing 203
Field Coil Checks 205
Field Coil Removal 205
Solenoid Checks 205
Test 205
Assembly 207
Pinion Clearance 208
MAGNETIC SWITCH 208
Coil Test 208
Electric Start System Wiring Diagrams 208
ENGINE PRELUB SYSTEM 209
OPERATION 209
Pressure Switch 209
Suction Line 209
Outlet Line 209
Check Valve 209
Solenoid Timer 209
TROUBLESHOOTING PRELUB STARTER CIRCUIT 211
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 215
24VDC ELECTRICAL SYSTEM COMPONENTS 217
PASSENGER SEAT BASE COMPARTMENT 217
COMPONENTS 217
Taillight Resistor Diode Assemblies 217
Inclinometer 217
Brake Warning Buzzer (BWB) 217
Lubrication System Timer 217
Three Minute Idle Timer Components 217
Three Minute Idle Timer 219
Idle Timer Relay 219
Three Minute Idle Contactor 219
Three Minute Idle Circuit Test 219
Data Store Button 219
Komatsu Engine Quantum Connector (Not Used) 219
Komatsu Engine Cense Connector 219
STATEX III Propulsion System Diagnostic Connector 219
Modular Mining Port (Optional) 219
Alarm Indicating Device (AID) System 220
Diode Matrix (Without Sound) 220
Diode Matrix (With Sound) 221
Hot Switch Inverter 221
Hot Switch Inverter Card (Slot 4) (Not Used) 221
Temperature 221
Oil Level 221
Temperature and Latch 221
Coolant Level/Flasher 222
Lamp Test 222
BATTERY EQUALIZER BOX 222
Troubleshooting 222
BODY-UP SWITCH 223
Adjustment 223
Service 223
HOIST LIMIT SWITCH 224
Adjustment 224
Service 224
24-VOLT RELAY AND DIODE BOARDS 224
RELAY BOARDS 225
Description 225
SERVICE 225
To Replace A Relay: 225
To Replace A Circuit Breaker: 225
To Replace A Circuit Panel Card 226
Relay Board Components 226
Installing Additional Circuits 227
DIODE BOARD 1 228
Diode Testing 228
CIRCUIT BREAKERS 230
SECTION D10 BATTERY CHARGING ALTERNATOR INDEX 231
BATTERY CHARGING SYSTEM 235
BATTERY CHARGING SYSTEM 235
ELECTRICAL SYSTEM DESCRIPTION 235
CHARGE VOLT AND AMP VALUES 235
BATTERY 235
Maintenance and Service 235
Troubleshooting 236
Undercharging 236
Overcharging 236
Corrosion 236
Acid Levels 236
Non-Use or Storage 236
Freezing 237
BATTERY CHARGING ALTERNATOR 238
GENERAL INFORMATION 238
General Description 238
Terminal Identification and Location 239
Battery Positive (B+) 239
Battery Negative (B-) 239
DC Output (D+) 239
AC Output (R) 239
Regulator Harness Plug Identification 239
Alternator Specifications 239
Performance Curve 239
Battery/Alternator Terminology 240
WIRING DIAGRAM 242
DIMENSIONS AND TORQUE VALUES 243
PERIODIC MAINTENANCE 244
TESTING 244
GENERAL INFORMATION 244
Troubleshooting Alternator (On-Truck) 244
Equipment Required 244
Preliminary Checks 244
Test Set-up 246
Test Procedure 247
REGULATOR TESTING 248
Regulator Bypass Test (No Output) 248
Regulator Bypass Test (Amp Rating) 249
BENCH TESTING 250
Equipment 250
Identification Record 250
Advanced Troubleshooting 250
Bench Test 1: No-Load Test 250
Bench Test 2: Full Load Test 251
Bench Test 3: Regulator Bypass Test 251
STATIC TESTING 252
Equipment 252
Identification Record 252
Regulator Tester 252
Check For Shorted Power Transistor 252
Circuit Tests 253
FIELD COIL TESTS 254
Field Coil Test 1: Check for Open or Shorted Field Coil 254
Field Coil Test 2: Check For Grounded Field Coil 254
STATOR TESTS 255
Stator Test 1: Check For Stator-To-Stator Continuity 255
Stator Test 2: Check For Grounded Stators 256
THERMAL SWITCH TEST 256
Initial Test 256
Verifying a Faulty Thermal Switch 257
TROUBLESHOOTING TIPS 258
ALTERNATOR 262
ALTERNATOR REPAIR 262
Removal 262
Installation 264
Special Tools and Lubricants 264
Epoxy Adhesive 265
Liquid Threadlockers 265
Elastoplastic Silicone Resin 265
ALTERNATOR EXPLODED VIEW 267
ALTERNATOR DISASSEMBLY 269
Regulator Removal 269
Fan Removal 270
Pulley Removal 271
Anti-Drive End Housing Removal 271
Anti-Drive End Rotor Removal 273
Drive End Housing Removal 275
Drive End Rotor Removal 281
Field Coil Removal 282
Drive End and/or Anti-Drive End Stator Removal 284
CLEANING AND INSPECTION 286
ALTERNATOR ASSEMBLY 286
Anti-Drive End Stator Installation 286
Drive End Stator Installation 288
Field Coil Installation 291
Drive End Bearing Installation 293
Drive End Rotor Installation 295
Rotor and Rotor Shaft Installation 295
Drive End Housing Installation 296
Anti-Drive End Rotor Installation 300
Anti-Drive End Housing Installation 301
Regulator Installation 304
THERMAL SWITCH 305
Removal 305
Installation 307
SUPPORT STAND 307
SECTION D35 PAYLOAD METER III INDEX 309
OPERATION SECTION 313
Introduction 313
Data Summary 313
Data Gathering 313
COMPONENT DESCRIPTION 314
System Diagram 314
Suspension Pressure Sensors 314
Inclinometer 314
Operator Display 314
Operator Switch 315
Speed Input 315
Body-Up Switch 315
Brake Lock Switch 315
Payload Meter 315
Communications Ports 315
Key Switch Input 316
Payload Meter Power 316
Load Lights 316
Wiring and Termination 317
TCI Outputs 317
OPERATOR’S DISPLAY AND SWITCH 318
Reading the Speedometer 318
Reading the Load Display 318
Using the Operator ID 318
Using the Load and Ton Counter 318
Total Ton Counter 318
Total Load Counter 319
Clearing the Counters 319
Viewing Live Sensor Data 319
Other Display Messages 319
PAYLOAD OPERATION & CALCULATION 320
Description of Haul Cycle States 320
Haul Cycle Description 320
Load Calculation 321
Carry Back 321
Measurement Accuracy 321
SOURCES FOR PAYLOAD ERROR 321
Payload Error 321
Loading Conditions 322
Pressure Sensors 322
Swingloads 322
Speed and Distance 322
HAUL CYCLE DATA 322
Haul Cycle Warning Flags 324
Frame Torque Data 325
Sprung Weight Data 325
Maximum Speed Data 325
Alarm Records 325
Fault Code Data 326
PC SOFTWARE OVERVIEW 327
System Configuration 327
Installing the PLMIII Software 327
DOWNLOADING DATA 328
PLM III SYSTEM CONFIGURATION 329
Starting Communications 329
Displayed Payload Units 329
Time Units 329
Connection Menu 329
Connecting to the Payload Meter 330
Configure the Payload Meter 330
Setting the Date and Time 330
Setting the Truck Type 331
Setting the Gauge Display Units 331
Setting the Frame Serial Number 331
Setting the Truck Number 331
Setting the Komatsu Distributor 331
Setting the Komatsu Customer 331
Clean Truck Tare 332
Inclinometer Calibration 332
DATA ANALYSIS 333
Creating a Query 333
Sorting on Truck Unit Number 333
Sorting on Truck Type 333
Sorting on Date Range 334
Sorting on Time Range 334
Payload Detail Screen 335
Creating Reports 335
Summary – one page report 336
Detailed – multi-page report 336
Creating Graphs 337
Exporting Data 337
CSV Export 337
Compressed 338
Importing Data 339
Deleting Haul Cycle Records 339
Viewing Alarms 340
Deleting Alarm Records 340
TROUBLESHOOTING SECTION 341
TROUBLESHOOTING 341
Viewing Active Alarms 341
Real-Time Data Display 341
Testing the Payload Lights 341
Creating Log Files of Inputs 342
Daily Inspections 342
Periodic Maintenance 342
Abnormal Displays at Power-Up 343
No Payload Display When Key Switch is Turned ON 344
No Display on Speedometer 345
No Display on Operator Display 345
No Communications With PC 346
Load Lights Don’t Light During Loading 347
Load Lights Remain ON 348
Load Lights Remain ON During Dumping 348
Display Doesn’t Clear When The Load Is Dumped 348
Calibration Problems 349
Alarm 1 – Left Front Pressure High 350
Alarm 2 – Left Front Pressure Low 350
Troubleshoot Wiring to Left Front Suspension 350
Alarm 3 – Right Front Pressure High 351
Alarm 4 – Right Front Pressure Low 351
Troubleshoot Wiring to Right Front Suspension 351
Alarm 5 -Left Rear Pressure High 352
Alarm 6 – Left Rear Pressure Low 352
Troubleshoot Wiring to Left Rear Suspension 352
Alarm 7 – Right Rear Pressure High 353
Alarm 8 – Right Rear Pressure Low 353
Troubleshoot Wiring to Right Rear Suspension 353
Alarm 9 – Inclinometer High 354
Alarm 10 – Inclinometer Low 354
Troubleshoot Inclinometer Wiring 354
Alarm 13 – Body Up Input Failure 355
Alarm 16 – Memory Write Failure 356
Alarm 17 – Memory Read Failure 356
Alarm 18 357
Alarm 19 357
Alarm 22 357
Operator Switch Doesn’t Work 358
Alarm 26 – User Switch Fault – SELECT 358
Alarm 27 – User Switch Fault – SET 358
Connector Map 359
Connectors 360
PLMIII CHECK OUT PROCEDURE 361
General Description 361
Tools Required 361
Checkout Procedure 361
PLMIII CHECKOUT PROCEDURE CONFIRMATION 365
Flashburn Programming 365
Confirmation Checklist 367
SECTION E ELECTRICAL PROPULSION INDEX 369
SECTION E2 ELECTRICAL PROPULSION COMPONENTS 371
ELECTRICAL PROPULSION COMPONENTS 375
GENERAL SYSTEM DESCRIPTION 375
CONTROL SYSTEM 375
System Operation 376
FL275 Panel 377
CARD REPLACEMENT 378
Removal 378
Installation 378
Card Repair 378
Panel Wiring 378
COMPUTER DESCRIPTION 379
Microprocessor 379
Download Capability 379
SOFTWARE 379
Base Monitor Program 379
Runtime Monitor Program – OBJ Running Code 379
Configuration Software – CFG 380
PTU – Portable Test Unit Code 380
System Regulation 380
Propulsion 381
Retarding 381
TWO-DIGIT DISPLAY PANEL 382
The Coded Number 382
Events 382
Frames 383
Windows 383
System Categories 383
Limits On Resetting Faults 383
NA Faults 384
Event Sequence 384
Resetting Events 384
Event Descriptions 384
Subcode Descriptions 384
2-DIGIT DISPLAY PANEL SUBCODES 392
PORTABLE TEST UNIT (PTU) 395
DESCRIPTION 395
Operational Hints 395
SOFTWARE INSTALLATION PREPARATION 396
HARD DISK SPACE REQUIREMENTS 396
SOFTWARE INSTALLATION ON PTU 396
PTU/Truck Communication Problems 397
THE MAIN MENU 398
Quit Menu 398
PTU Talk To Truck 398
View PTU Saved Files 398
List Stat Data Files 398
Truck Setup (CFG) 398
Select Truck Setup 398
Update CFG Version 398
Change PTU Password 398
CONFIGURATION (CFG) FILE CONVERSION 400
Conversion Procedure 400
Convert Old CFG files for New software 401
STATEX CONFIGURATION FILES 404
0) Source Directory: 404
1) Select A Truck Configuration 405
2) View Truck Configuration: Data Curves 406
3) Change/View Serial and Model Numbers 407
4) View Options 407
5) Change/View Truck Specifics 409
6) Change/View Overspeeds 411
7) Save a Truck Configuration, filename: 412
8) Save Directory: 413
CHANGE PTU PASSWORD 414
PROGRAMMING THE TRUCK 415
Connect PTU to the Truck 415
Select Configuration File 415
Activate The PTU Mode 415
Check Object Code Version 416
Download Configuration Files 417
Date And Time 418
Event Data 419
Statistical Data 421
View Counters 421
View Profiles 421
Upload Statistical Data To A File 421
Statistical Data Codes – Counters 422
STATISTICAL DATA CODES – COUNTERS 423
STATISTICAL DATA CODES – PROFILES 428
TRUCK SPECIFIC INFORMATION 432
Temporary Truck Settings 433
MISCELLANEOUS FEATURES 434
Saving Data 434
PTU Abbreviations 435
Other Menu Selections 435
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 436
ALTERNATOR 436
ELECTRIC WHEEL MOTORS 436
RETARDING GRIDS 436
ELECTRONIC ACCELERATOR AND RETARD PEDALS 436
Removal 436
Installation 436
Disassembly 437
Reassembly 437
COOLING BLOWER WARNING SYSTEM 437
Operation 437
Test 437
Removal 438
Installation 438
ELECTRICAL CONTROL CABINET 439
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 444
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 445
SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 447
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 451
GENERAL INFORMATION 451
COMMUNICATIONS PORT CHECK 452
PTU Hookup 452
4 0 SEQUENCE TESTS – (ENGINE NOT ON) 453
Preparation and Setup 453
CONTROL SYSTEM SELF-TEST 454
4 1 THROTTLE SYSTEM CHECK AND ADJUSTMENT 454
4 2 RETARD SYSTEM CHECK AND ADJUSTMENT 455
PTU Setup 455
4 3 REVERSER AND PROPULSION CONTACTORS CHECK 456
4 4 NOT USED 457
4 5 RETARD CONTACTORS OPERATION CHECK 457
4 6 GROUND FAULT SENSING CHECK 457
4 7 GROUND FAULT IN RETARD OPERATION CHECK 458
4 8 OVERRIDE OPERATION CHECK 458
4 9 ANTI-REVERSAL FUNCTION (AR) CHECK 459
4 10 OVERSPEED RETARD OPERATION CHECK 459
4 11 HOIST INTERLOCK OPERATION CHECK 460
4 12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK 460
Return to Main Menu 460
5 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 461
5 1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU 461
5 2 DIGITAL INPUT CHECKS 462
5 3 DIGITAL OUTPUT CHECKS 463
6 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 467
6 1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU 467
6 2 ANALOG INPUT CHECKS 468
6 3 FREQUENCY INPUT CHECKS 472
Return to Main Menu 473
7 0 SPEED EVENT CHECKS 473
Preparation and Setup 473
Setup PTU 473
7 1 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK 474
7 2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK 474
7 3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK 474
7 4 OTHER SPEED EVENTS CHECKS 474
Return to Main Menu 474
8 0 RETARD SPEED CONTROL SYSTEM CHECK 475
Preparation and Setup 475
Setup PTU 475
8 1 OVERSPEED PICKUP AND DROPOUT CHECK 475
8 2 RETARD POT MAXIMUM SETTING CHECK 475
8 3 RETARD POT MINIMUM SETTING CHECK 475
8 4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL 476
Return to Main Menu 476
9 0 LOAD TEST USING TRUCK RETARD GRIDS 476
Setup and Preparation 476
PTU Setup 476
9 1 LOAD TEST 477
10 0 MOTOR FIELD CURRENT CHECK IN RETARDING 477
Setup PTU 477
10 1 RETARD CHECK 478
11 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 479
11 1 BRAKE SYSTEM INTERLOCKS CHECK 479
Preparation 479
11 2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT 479
11 3 SYNC TRANSFORMER CHECKOUT 480
11 4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT 480
11 5 BATTERY BOOST ADJUSTMENT 480
11 6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST 480
11 7 MOTOR ROTATION TEST 481
11 8 GROUND FAULT CHECKS 481
12 0 MISCELLANEOUS CHARTS 482
12 1 WHEEL MOTOR GEAR RATIOS 482
12 2 MAXIMUM ALLOWABLE TRUCK SPEEDS 483
12 3 ENGINE OPTIONS 484
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX 485
SECTION G2 TIRES AND RIMS INDEX 487
GENERAL INFORMATION 489
TIRES 489
Handling Tires 489
Tire Maintenance 490
Storing Tires After Removal 490
FRONT TIRES AND RIMS 491
Removal 491
Installation 492
REAR TIRES AND RIMS 493
Removal 493
Installation 494
RIM 495
Tire Removal 495
RIM AND TIRE PREPARATION 496
LUBRICANTS 496
TIRE INSTALLATION 497
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 499
FRONT WHEEL HUB AND SPINDLE 501
WHEEL HUB AND SPINDLE ASSEMBLY 501
Removal 501
Installation 503
Disassembly 504
Cleaning and Inspection 505
Assembly 505
Wheel Bearing Adjustment (Spindle Vertical) 508
Wheel Bearing Adjustment (Tire Mounted) 509
STEERING CYLINDERS AND TIE ROD 513
Spherical Bearing Wear Limits 513
Removal 514
Installation 516
Bearing Replacement 516
TOE-IN ADJUSTMENT 517
SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX 519
PIVOT PIN 521
Removal 521
Installation 522
PIVOT EYE BEARING 522
Disassembly 522
Assembly 523
PIVOT EYE REPAIR 523
Removal 523
Disassembly 523
Bushing (New) 523
Pivot Eye Bore (New) 523
Assembly 523
Installation 524
ANTI-SWAY BAR 524
Removal 524
Installation 524
Disassembly 525
Cleaning and Inspection 525
Assembly 525
SECTION G5 REAR AXLE HOUSING INDEX 527
REAR AXLE HOUSING 529
REAR AXLE HOUSING 529
Removal 529
Installation 529
WHEEL MOTOR 529
Removal 529
Cleaning and Inspection 530
Installation 530
Maximum Cap Screw Usage 530
SECTION H SUSPENSIONS INDEX 531
SECTION H2 FRONT SUSPENSION INDEX 533
Removal 535
Installation 537
Angle Advance Tightening Procedure 538
Disassembly 539
Cleaning and Inspection 540
Assembly (Bearing Only) 540
Suspension Assembly (Complete) 540
SUSPENSION PRESSURE TEST 542
SECTION H3 REAR SUSPENSIONS INDEX 545
REAR SUSPENSIONS 547
Removal 548
Installation 550
Disassembly 550
Cleaning and Inspection 550
Assembly 551
SUSPENSION PRESSURE TEST 553
SECTION H4 OILING AND CHARGING PROCEDURES INDEX 555
GENERAL 557
EQUIPMENT LIST 557
Hydrair® Charging Kit 557
Installation of Charging Kit 557
Removal of Charging Kit 558
Support Blocks For Oiling and Charging Dimensions 558
FRONT SUSPENSION 559
Front Suspension Oiling 559
Front Suspension Nitrogen Charging 560
REAR SUSPENSION 562
Rear Suspension Oiling 562
Rear Suspension Nitrogen Charging 564
SECTION J BRAKE CIRCUIT INDEX 567
SECTION J2 BRAKE CIRCUIT INDEX 569
GENERAL DESCRIPTION 571
SERVICE BRAKE CIRCUIT 571
SECONDARY BRAKING AND AUTOMATIC APPLY 573
PARKING BRAKE CIRCUIT 573
Normal Operation (key switch on, engine on) 573
BRAKE LOCK CIRCUIT 574
WARNING CIRCUIT 574
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 577
BRAKE CIRCUIT COMPONENT SERVICE 579
BRAKE VALVE 579
Rebuild Criteria 579
Removal 579
Installation 581
Disassembly 583
Cleaning and Inspection 585
ASSEMBLY 585
Actuator Base Threaded Inserts 585
Boot and Cap 585
Valve Body Seal Installation 586
Regulator Sleeve O-Ring Installation 587
Actuator Plunger O-Ring Installation 587
Assembly of Valve 587
DIFFERENTIAL PRESSURE SWITCH 588
Disassembly 589
Cleaning and Inspection 589
Assembly 589
VALVE BENCH TEST AND ADJUSTMENT 589
Test Set Up Procedure 591
Brake Valve Output Pressure Adjustment 591
Differential Pressure Switch Test 592
Final Test and Adjustment 592
Installation Of Brake Pedal Actuator Assembly to Brake Valve 593
HYDRAULIC BRAKE ACCUMULATORS 595
Brake Accumulator Bleed-Down Procedure 595
Removal 595
Installation 597
Disassembly 597
Cleaning and Inspection 599
Assembly 599
Leak Testing 602
BRAKE ACCUMULATOR CHARGING 603
Temperature During Precharge 605
ACCUMULATOR STORAGE 605
Installation 606
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 607
BRAKE CIRCUIT CHECK-OUT PROCEDURE 609
EQUIPMENT REQUIRED 612
INITIAL SYSTEM SET-UP 613
Parking Brake 613
Service Brakes 614
Brake Lock/Secondary 614
Low Brake Pressure and Auto Apply 615
Reapplications 615
Differential Pressure Switch 615
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 617
The Brakes are Locked, Service, and/or Parking 617
Both Brake Circuits are Dragging 617
One Brake Circuit is Dragging 617
Brakes are Not Going to Full Pressure 617
A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off 617
Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released 618
Differential Pressure Warning Circuit is Not Operating 618
A Low Brake Pressure Warning Occurs When Brakes are Applied 618
Low Pressure Warning Circuit Not Operating Properly 618
Low Pressure Warning is On Even Though System Pressure is Correct 619
Low Pressure Warning Comes On and Pressure is Low 619
A Squeal is Heard When Controller is Operated 619
Output Pressure At Controller is Correct but Brakes are Not Applying 619
Brake Pressures Drift Excessively While Pedal is Held Steady 619
Oil is Leaking Around the Pedal Base 619
Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM 619
CHECK-OUT PROCEDURE 620
HYDRAULIC BRAKE SYSTEM DATA SHEET 620
SECTION J5 FRONT DISC BRAKES INDEX 623
BRAKE CALIPER 625
Removal 625
Installation 626
Disassembly 627
Cleaning and Inspection 627
Assembly 629
BRAKE LINING 629
Replacement 629
FRONT SERVICE BRAKE BURNISHING 631
BRAKE BLEEDING PROCEDURE 632
REAR DISC BRAKES 635
REAR BRAKES 635
CALIPER, DISC, AND PARKING BRAKE 635
Removal 635
Installation 636
CALIPER PISTON 638
Piston Assembly Removal 638
Inspection 638
Piston Assembly Installation 639
FUNCTIONAL TEST OF PISTON ASSEMBLY 640
Return Spring Force 640
Built-In Clearance 640
Grip Force 642
Grip Force Measurement 643
Spring Force Measurement 645
Disassembly of Piston Assembly 646
Assembly of Piston Assembly 647
BENCH TEST 647
BRAKE LINING 648
Replacement 648
SERVICE BRAKE BURNISHING 651
SAFETY PRECAUTIONS 651
Rear Brake Burnishing 652
BRAKE BLEEDING PROCEDURE 653
Spring Force Measurement 654
SECTION J6 REAR BRAKES INDEX 633
SECTION J7 PARKING BRAKE INDEX 655
GENERAL INFORMATION 657
PARKING BRAKE CALIPER 657
Lining Thickness Inspection 657
Removal 658
Installation 658
Parking Brake Adjustment 659
Parking Brake Caliper Disassembly 660
Cleaning and Inspection 661
Parking Brake Caliper Assembly 662
PARKING BRAKE LINING REPLACEMENT 662
PARKING BRAKE BURNISH PROCEDURE 662
Lining Conditioning 662
BRAKE BLEEDING PROCEDURE 663
SECTION L HYDRAULIC SYSTEM INDEX 665
SECTION L2 HYDRAULIC SYSTEM OVERVIEW 667
HYDRAULIC SYSTEM OVERVIEW 668
Hoist Circuit Operation 668
Steering, Brake and Pantograph Circuit Operation 668
Axle Blower System Operation 668
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 671
HYDRAULIC SYSTEM COMPONENT REPAIR 673
HOIST PUMP 673
Removal 673
Installation 675
Disassembly 675
Inspection 678
Assembly 679
PISTON PUMP 684
Removal 684
Installation 685
Disassembly 687
Inspection of Parts 693
Assembly 695
AXLE BLOWER HYDRAULIC MOTOR 700
Removal 700
Installation 700
Rear Axle Blower Housing 700
Disassembly 700
Assembly 701
Disassembly 703
Inspection 705
Assembly 706
Trouble Shooting 707
Hand Wheel Control 708
Disassembly 708
Assembly 708
HYDRAULIC TANK 710
Filling Instructions 710
Removal 711
Installation 711
HYDRAULIC TANK STRAINER AND DIFFUSER 712
Removal 712
Inspect and Clean 713
Installation 713
SECTION L4 STEERING CIRCUIT 715
STEERING CIRCUIT 717
STEERING CIRCUIT OPERATION 717
COMPONENT DESCRIPTION 718
Steering Control Valve 718
Unloader Valve 719
Bleed-Down Manifold Valve 719
Flow Amplifier 725
FLOW AMPLIFIER SYSTEM OPERATION 726
No Steer 726
Steering Left 728
Steering Right 730
No Steer, External Shock Load 732
Steering Pump 734
High Pressure Filter 734
Accumulators 734
Low Precharge Warning Switch 734
SECTION L5 STEERING CONTROL VALVE INDEX 735
Removal 737
Installation 738
STEERING CONTROL VALVE REBUILD 739
Disassembly 739
Cleaning and Inspection 740
Assembly 740
BRAKE / STEERING PUMP 744
Removal 744
Installation 746
Disassembly 747
Inspection of Parts 747
Assembly 749
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 751
STEERING CIRCUIT COMPONENT REPAIR 753
BLEED-DOWN MANIFOLD 753
Removal 753
Installation 753
ACCUMULATOR 754
Removal 754
Installation 755
Disassembly 756
Cleaning and Inspection 756
Assembly 757
Leak Testing 758
STEERING ACCUMULATOR CHARGING 759
Temperature During Precharge 762
ACCUMULATOR STORAGE 763
Installation 763
FLOW AMPLIFIER 764
Removal 764
Installation 764
Disassembly 765
Assembly 768
STEERING CYLINDERS 769
Disassembly 769
Piston Seal and Bearing Installation 769
Cylinder Assembly 769
Test 769
TROUBLESHOOTING CHART 772
SECTION L7 HOIST CIRCUIT INDEX 777
HOIST CIRCUIT OPERATION 779
COMPONENT DESCRIPTION 780
Hydraulic Tank 780
Hydraulic Pump 780
High Pressure Filter 780
Hoist Valve 780
Hoist Pilot Valve 781
Bleed-Down Manifold 782
Counterbalance Manifold 782
Hoist-Up Limit Solenoid 782
Pilot Operated Check Valve 782
HOIST VALVE OPERATION 784
Float Operation 784
Power Up Operation (Figure 7-6) 786
Hold Operation (Figure 7-7) 788
Power Down Operation (Figure 7-8) 790
Float Operation (Figure 7-9) 792
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR 795
HOIST CIRCUIT COMPONENT REPAIR 797
HOIST VALVE 797
Removal 797
Installation 797
O-Ring Replacement 799
INLET SECTION 800
Disassembly 800
Cleaning and Inspection 801
Assembly 801
REAR SPOOL SECTION (WORK PORTS) 802
Disassembly 802
Cleaning and Inspection 804
Assembly 804
HOIST PILOT VALVE 806
Removal 806
Installation 806
Disassembly 807
Cleaning and Inspection 808
Assembly 808
HOIST UP LIMIT SOLENOID VALVE 809
HOIST CYLINDERS 809
Removal 809
Installation 810
Disassembly 813
Cleaning and Inspection 814
SS1143 Tightening Tool – Assembly Drawing 815
ASSEMBLY OF QUILL AND CYLINDER 815
Quill Installation 815
Installation Of Check Balls And Plugs In Quill 816
Assembly of Cylinder 818
COUNTERBALANCE MANIFOLD 819
SECTION L9 HIGH PRESSURE FILTERS INDEX 821
HOIST CIRCUIT FILTER 823
Filter Element Replacement 823
Removal 824
Installation 824
Indicator Switch 824
STEERING CIRCUIT FILTER 825
Filter Element Replacement 825
Removal 826
Installation 826
Indicator Switch 826
INDICATOR SWITCH 826
Test Procedure 826
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE 829
Initial Start Up and Flushing (Steps 5 – 22) 830
Component Checkout and Adjustment (Steps 23 – 34) 831
Adjustment Procedure for Hoist Counterbalance Cartridge Valve (Steps 34a-34l) 833
Counterbalance Valve Adjustment (Steps f & g): 834
Manifold reassembly (steps i through k): 834
Piston Pump and Axle Box Hydraulic Motor Adjustment (Steps 35 – 50) 835
Oil Cleanliness Check 836
Oil Sampling Location on Truck: 836
Oil Sampling Process and Cleanliness Criteria: 836
DISABLED TRUCK DUMPING PROCEDURE 837
HOOKUP 837
DUMPING PROCEDURE 837
Raising the Body: 837
Lowering the Body: 837
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 845
SECTION M4 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM INDEX 847
SYSTEM ADJUSTMENT 849
PUMP 852
Removal 852
Disassembly 852
Inspection 852
Assembly 852
Installation 852
BLOWER DRIVE MOTOR 855
Removal 855
Disassembly 855
Inspection Of Parts 856
Assembly 857
Installation 858
BLOWER BEARING REPAIR 858
Removal 858
Replacement 858
Assembly 859
AIR CLEANER 859
Assembly 859
Removal 859
Assembly 859
SECTION M7 HEATER OPTIONS INDEX 861
GENERAL INFORMATION 863
TROUBLESHOOTING 863
HEATER ELEMENT 863
Removal 863
Installation 864
GENERAL 865
Maintenance 865
HEATING ELEMENT 865
Removal 865
Installation 866
THERMOSTAT 866
Removal 866
Installation 866
GENERAL INFORMATION 867
TROUBLESHOOTING 867
HEATER ELEMENT 867
Removal 867
Installation 868
SECTION M8 SPECIAL TOOLS INDEX 869
SPECIAL TOOLS 871
SECTION M19 RADIATOR SHUTTERS INDEX 879
SECTION N OPERATOR’S CAB INDEX 889
SECTION N2 TRUCK CAB INDEX 891
TRUCK CAB 893
TRUCK CAB 893
Description 893
Removal 894
Installation 896
CAB DOOR 896
Removal 896
Installation 897
Door Adjustment 897
Door Jam Bolt Adjustment 897
Door Handle Plunger Adjustment 899
Replace Door Glass 900
Replace Door Window Regulator 904
Replace Door Handle or Latch Assembly 904
Door and Door Hinge Seal Replacement 905
Door Opening Seal Removal 905
Installation 905
GLASS REPLACEMENT 906
Adhesive-Bonded Windows 906
Recommended Tools/Supplies 906
Replacement Procedure 906
Windshield and Rear Glass 907
Removal 907
Installation 908
Removal and Installation of Operator Seat 909
Inspection 909
Removal 909
Installation 909
Removal and Installation of Passenger Seat 910
Removal 910
Installation 910
SECTION N3 CAB COMPONENTS INDEX 911
WINDSHIELD WIPERS 913
WIPER MOTOR REPLACEMENT 913
Removal 913
Installation 913
WIPER ARM REPLACEMENT 913
Removal 913
Installation 914
WIPER LINKAGE REPLACEMENT 914
Removal 914
Installation 915
WINDSHIELD WASHER 915
Operation 915
Service 915
SEAT BELT 916
Removal 916
Installation 916
SECTION N4 OPERATOR COMFORT INDEX 919
HEATER/AIR CONDITIONER 923
CONTROLS 923
Operation 923
Heater/Air Conditioner Vents 923
Defroster Vent Control Switch 923
Heat Control Switch 923
Temperature Control Knob 923
Fan Control Knob 923
Heater/Air Conditioner Selector Switch 923
COMPONENTS 924
Circuit Breakers 924
Relays 924
Heater Core 924
Fan Motor and Speed Control 925
Test 925
Actuators 925
Test 925
Cab Air Filter 926
AIR CONDITIONING SYSTEM 928
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 929
PRINCIPLES OF REFRIGERATION 929
Air Conditioning 929
Refrigeration – The Act of Cooling 930
The Refrigeration Cycle 930
AIR CONDITIONER SYSTEM COMPONENTS 931
Compressor (Refrigerant Pump) 931
Service Valves 931
Receiver-Drier 931
Condenser 931
Expansion Block Valve 932
Accumulator 932
Evaporator 933
ELECTRICAL CIRCUIT 933
Thermostat 933
Compressor Clutch 934
Trinary™ Switch 934
SYSTEM SERVICING 936
SERVICE TOOLS AND EQUIPMENT 937
Recovery/Recycle Station 937
Leak Detector 938
Service Valves 938
Vacuum Pump 938
Manifold Gauge Set 939
Low Side Gauge 939
High Side Gauge 939
Installing Manifold Gauge Set 940
Purging Air From Service Hoses 940
SYSTEM PERFORMANCE TEST 941
SYSTEM OIL 942
Handling and Reusing RPAG Oil 942
Oil Quantity 942
Checking System Oil 942
REFRIGERANT 943
Recycled Refrigerant 943
Reclaimed Refrigerant 943
Refrigerant Quantity 944
R-134a Refrigerant Containers 944
SYSTEM LEAK TESTING 944
Electronic Leak Detector 945
Tracer Dyes 945
Soap and Water 945
RECOVERING AND RECYCLING THE REFRIGERANT 945
Performing the Recovery Cycle 945
Performing the Recycling Procedure 946
Evacuating and Charging the A/C System 946
SYSTEM REPAIR 946
System Flushing 947
COMPONENT REPLACEMENT 947
Hoses and Fittings 947
Lines 947
Expansion Valve 948
Receiver-Drier 948
Thermostat 948
Compressor 948
Accumulator 949
Clutch 949
Servicing the Compressor Clutch 950
Pulley Removal 952
Clutch Coil Check 952
Pulley Installation 953
Clutch Assembly Installation 953
EVACUATING THE SYSTEM 954
CHARGING THE A/C SYSTEM 956
AIR CONDITIONER DRIVE BELT 956
Pulley Alignment 956
Belt Tension 957
TROUBLESHOOTING 958
Preliminary Checks 958
Diagnosis of Gauge Readings and System Performance 959
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 960
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 966
SECTION N5 OPERATOR CONTROLS 967
OPERATOR CONTROLS 969
STEERING WHEEL AND CONTROLS 970
STEERING WHEEL 970
HORN BUTTON 970
TILT/TELESCOPE LEVER 970
MULTI-FUNCTION TURN SIGNAL SWITCH 970
Turn Signal Operation 971
High Beam Headlight Operation 971
Windshield Wiper Operation 971
STEERING COLUMN 971
Removal 971
Inspection 972
Installation 972
PEDALS 972
SERVICE BRAKE PEDAL 972
DYNAMIC RETARDER PEDAL 973
Optional – Dual Function/Single Pedal 973
THROTTLE PEDAL 973
OVERHEAD PANEL CONTROLS AND COMPONENTS 974
GRADE/SPEED WARNING CHART 974
RADIO SPEAKERS 974
WINDSHIELD WIPERS 974
WARNING ALARM BUZZER 974
CAB RADIO 974
WARNING LIGHTS DIMMER CONTROL 974
WARNING/STATUS INDICATOR LIGHT PANEL 974
AIR CLEANER VACUUM GAUGES 974
CENTER CONSOLE 975
TRUCK CONTROLS 975
F-N-R Selector Switch 975
Hoist Control Lever 975
Trolley Master Control Lever 975
CONSOLE SWITCHES AND CONTROLS 975
Cigarette Lighter 975
Window Control Switches 975
Engine Shutdown Switch 975
Override Switch 977
Retard Speed Control (RSC) Switch 977
Retard Speed Control (RSC) Dial 977
Statex III Download Port 978
Engine Diagnostic Port (CENSE) 978
Engine Diagnostic Connectors 978
Data Storage Button 978
Passenger Seat 978
PAYLOAD METER 979
Payload Meter Download Connector 979
CAB CLIMATE CONTROL 980
HEATER/AIR CONDITIONER VENTS 980
HEATER/AIR CONDITIONER CONTROLS AND VENTS 980
Defroster Vent Control Switch 980
Heat Control Switch 980
Temperature Control Knob 980
Fan Control Knob 980
Heater/Air Conditioner Vents 980
OPERATOR SEAT 981
ADJUSTMENT 981
INSTRUMENT PANEL 982
GENERAL INFORMATION 982
CONTROL SYMBOLS 982
CONTROL SWITCHES AND GAUGES 983
Key Switch 984
Engine Shutdown Switch With Timer Delay 984
Fog Light Switch 984
Ladder Light Switch 984
Backup Light Switch 984
Panel Illumination Lights 984
Cab Air Conditioner/Heater Vents 984
Engine Cold Weather Starting Aid Switch 984
Rotating Beacon Light Switch 985
Heated Mirror Switch 985
Wheel Brake Lock Switch 985
Parking Brake Switch 985
Digital Tachometer 985
Right Turn Signal Indicator Light 986
High Beam Headlight Indicator Light 986
Left Turn Signal Indicator Light 986
Digital Speedometer/Payload Meter Display 986
Voltmeter Gauge 986
Engine Oil Pressure Gauge 986
Engine Water Temperature Gauge 986
Fuel Gauge 986
Engine Hourmeter 986
Headlight Switch 987
Panel Illumination Lights Dimmer Rheostat 987
Payload Meter Switch 987
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL 988
INDICATOR LIGHT FUNCTIONS 989
High Hydraulic Oil Temperature 989
Low Steering Pressure 989
Low Accumulator Precharge Pressure Warning 989
Electric System Fault Warning 990
Low Brake Pressure Indicator 990
Low Hydraulic Tank Level 990
Low Automatic Lubrication System Pressure 990
Circuit Breaker Tripped 990
Hydraulic Oil Filter 990
Low Fuel Indicator 991
Parking Brake Indicator 991
Service Brake Indicator 991
Body Up Indicator 991
Dynamic Retarding Indicator 991
Stop Engine Warning 991
Backup Indicator 991
Engine Shutdown Timer Switch- Five Minute Idle 991
Retard Speed Control 991
Service Engine Indicator (AEM) 992
High Wheel Motor Temperature Indicator 992
Blower Fault Warning 992
Service Engine Indicator (CENSE) 992
Komatsu Engines w/Centry™ Fuel Control 992
Hazard Warning Light Switch 992
Lamp Test Switch/Centry™ Diagnostic Test Switch 992
CENTRY™ FUEL SYSTEM DIAGNOSTICS 996
GENERAL OPERATION 996
DETERMINING FAULT CODES 996
EXITING THE DIAGNOSTICS MODE 997
SECTION P LUBRICATION AND SERVICE INDEX 999
SECTION P2 LUBRICATION AND SERVICE INDEX 1001
GENERAL INFORMATION 1003
HYDRAULIC TANK SERVICE 1003
Adding Oil 1003
COOLANT LEVEL CHECK 1004
Radiator Filling Procedure 1004
Coolant Specifications 1004
Unacceptable Practices 1004
WHEEL MOTOR SERVICE 1004
RESERVE ENGINE OIL SYSTEM (Optional) 1005
Reserve Oil Tank Filling Procedure (Remote fill) 1005
Inline Screen 1005
QUICK FILL SERVICE CENTER 1006
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS 1008
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued) 1009
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1010
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1010
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1011
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 1012
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1013
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 1014
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1015
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1016
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1016
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1017
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1018
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1019
AUTOMATIC LUBRICATION SYSTEM 1021
GENERAL DESCRIPTION 1021
SYSTEM COMPONENTS 1022
Filter Assembly 1022
Hydraulic Motor and Grease Pump 1022
Reservoir 1022
Fixed Pressure Reducing Valve 1022
Flow Control Valve 1022
Solenoid Valve 1023
Vent Valve 1023
24VDC Lubrication Cycle Timer 1023
Time Delay Module 1023
Pump Cutoff Pressure Switch 1023
Unloader Valve 1023
Pressure Switch 1023
Pressure Gauge 1023
Manual Override Button 1023
Injectors 1023
SYSTEM OPERATION 1026
Normal Operation 1026
Pressure Failure Detection Circuits 1027
GENERAL INSTRUCTIONS 1028
LUBRICANT REQUIRED FOR SYSTEM 1028
SYSTEM PRIMING 1028
LUBRICANT PUMP 1029
Pump Housing Oil Level 1029
Pump Pressure Control 1029
FILTER AND RESERVOIR 1029
Filter Assembly Element 1030
INJECTORS (SL-1 Series H) 1030
Injector Specifications 1030
Injector Adjustment 1030
INJECTOR OPERATION 1032
SYSTEM CHECKOUT 1033
Lubrication Cycle Timer Check 1033
Lubrication Cycle Timer Adjustment 1034
PREVENTIVE MAINTENANCE INSPECTION 1034
10 Hour Lubrication System Inspection 1034
100 Hour Inspection 1034
250 Hour Inspection 1034
500 Hour Inspection 1035
1000 Hour Inspection 1035
PUMP REBUILD 1036
Disassembly 1036
Cleaning and Inspection 1036
Assembly 1038
VENT VALVE REBUILD 1039
Disassembly and Assembly 1039
SYSTEM TROUBLESHOOTING CHART 1040
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1045
AXLE BOX 1045
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1046
ARMATURE AREA 1046
AT TIRE CHANGE 1046
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1047
GENERATOR/ALTERNATOR 1047
GRID BLOWER MOTOR 1047
CONTROL EQUIPMENT CHECKS 1047
MOTORIZED WHEEL MAINTENANCE SCHEDULE 1048
VEHICLE OPERATIONS TESTS 1048
SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX 1043
SECTION R SYSTEM SCHEMATICS 1049
EF55 HYDRAULIC BRAKE SCHEMATIC 1050
EJ2730 HYDRAULIC SCHEMATIC 1051
XS1000 ELECTRICAL SCHEMATIC 1052

S.V 16/12/24