Komatsu 730E Trolley Dump Truck Shop Manual CEBM026100 PDF

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Komatsu 730E Trolley Dump Truck Shop Manual CEBM026100  – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E Trolley Dump Truck Shop Manual CEBM026100  – PDF DOWNLOAD

Language : English
Pages : 1098
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 730E Trolley Dump Truck Shop Manual CEBM026100  – PDF DOWNLOAD

• SERIAL NUMBERS
  A30431, A30432, A30460,
  A30461, A30463, A30464, &
  A30467 – A30469

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
MAJOR COMPONENT DESCRIPTION 11
SPECIFICATIONS 13
Komatsu SSA16V159 13
SECTION A3 GENERAL SAFETY AND OPERATION INDEX 15
GENERAL SAFETY AND OPERATION 18
PERSONAL SAFETY 18
Safety Rules 18
Truck Safety Features 18
Clothing And Personal Items 18
Unauthorized Modification 18
Leaving The Operator’s Seat 18
Mounting And Dismounting 19
Fire Extinguishers And First Aid Kits 19
Precautions For High Temperature Fluids 19
Asbestos Dust Hazard Prevention 20
Fire Prevention For Fuel And Oil 20
ROPS Precautions 20
Preventing Injury From Work Equipment 20
Precautions For Optional Attachments 20
Precautions When Starting The Machine 21
PRECAUTIONS FOR TRUCK OPERATION 21
Safety Is Thinking Ahead 21
Safety At The Work Site 21
Fire Prevention 21
Preparing For Operation 21
Ventilation For Enclosed Areas 21
Mirrors, Windows, And Lights 22
In The Operator’s Cab – Before Starting The Engine 22
Seat Belts 22
OPERATING THE MACHINE 22
Starting The Engine 22
Truck Operation – General 23
Traveling In The Truck 23
Precautions When Traveling In Reverse 23
Traveling On Slopes 24
Ensuring Good Visibility 24
Operating On Snow 24
Avoid Damage To The Dump Body 24
Driving Near High-Voltage Cables 24
When Loading The Truck 24
When Dumping 24
Working On Loose Ground 25
Parking The Machine 25
TOWING 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump-Starting With Booster Cables 26
Jump Starting With Receptacles 26
PRECAUTIONS FOR MAINTENANCE 27
BEFORE PERFORMING MAINTENANCE 27
Stopping The Engine Before Service 27
Warning Tag 27
Proper Tools 27
Securing The Dump Body 27
DURING MAINTENANCE 28
Personnel 28
Attachments 28
Working Under The Machine 28
Keeping The Machine Clean 28
Rules To Follow When Adding Fuel Or Oil 28
Radiator Coolant Level 28
Use Of Lighting 28
Precautions With The Battery 29
Handling High-Pressure Hoses 29
Precautions With High-Pressure Oil 29
Maintenance Near High Temperatures And High Pressures 29
Rotating Fan And Belts 29
Waste Materials 29
Use of Tie-Off Anchor During Maintenance and Repair 29
TIRES 30
Handling Tires 30
Tire Maintenance 31
Storing Tires After Removal 31
ADDITIONAL JOB SITE RULES 32
WHEN REPAIRS ARE NECESSARY 33
OPERATING INSTRUCTIONS 34
PREPARING FOR OPERATION 34
SAFETY IS THINKING AHEAD 34
WALK AROUND INSPECTION 34
ENGINE START-UP 38
AFTER ENGINE HAS STARTED 39
EMERGENCY STEERING SYSTEM 40
Operation 40
Pre-Operation Testing 40
Additional Guidelines 41
MACHINE OPERATION SAFETY PRECAUTIONS 41
LOADING 42
HAULING 42
PASSING 43
DUMPING 43
To Raise The Dump Body: 43
To Lower The Dump Body: (When dumping over a berm or into a crusher): 44
To Lower The Dump Body (When dumping on flat ground): 44
TOWING 45
Towing Procedure 45
SAFE PARKING PROCEDURES 46
ENGINE SHUTDOWN PROCEDURE 46
DELAYED ENGINE SHUTDOWN PROCEDURE 46
SUDDEN LOSS OF POWER 47
TROLLEY OPERATING INSTRUCTIONS 48
AFTER THE ENGINE HAS STARTED 48
OPERATING IN DIESEL MODE 48
OPERATING IN TROLLEY LINE MODE 49
GETTING ON LINE 49
Operating On Trolley 51
GETTING OFF LINE 52
LINE STATUS SIGNALS 52
LINE STATUS SIGNAL MARKINGS 53
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION 53
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK 54
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS 54
TRUCK FAILURE WHILE ON TROLLEY 54
SECTION A4 WARNINGS AND CAUTIONS 57
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 67
SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX 77
SHORT TERM IDLE PERIODS 79
PREPARATION FOR STORAGE 80
REMOVAL FROM STORAGE 81
RECONDITIONING AN IDLE VEHICLE 82
ENGINE OPERATION 85
After The Engine Has Started 85
ENGINE STORAGE 86
Temporary Storage (30 Days Or Less) 86
Extended Storage (More Than 30 Days) 87
RESTORING AN ENGINE AFTER EXTENDED STORAGE 88
ELECTRIC DRIVE TRUCKS 89
Storing A Truck That Is Operational 89
Storing A Truck That Is Not Operational 90
Storing A Major Component 91
Periodic Inspections 91
Placing Equipment Into Service After Storage 91
SECTION B STRUCTURES INDEX 93
SECTION B2 STRUCTURAL COMPONENTS INDEX 95
STRUCTURAL COMPONENTS 97
LADDERS 97
Removal 97
Installation 97
GRILLE AND HOOD 98
Removal 98
Installation 98
RIGHT-HAND DECK 98
Removal 98
Installation 100
CENTER DECK 100
LEFT-HAND DECK 101
Removal 101
Installation 101
SECTION B3 DUMP BODY INDEX 103
DUMP BODY 105
Removal 105
Installation 106
BODY SLING 106
BODY PADS 107
BODY GUIDE 107
Adjustment 107
BODY POSITION INDICATOR 108
HOIST LIMIT SWITCH 108
ROCK EJECTORS 108
Inspection 108
SECTION B4 FUEL TANK INDEX 109
FUEL TANK 111
Removal 111
Repair 111
Cleaning 111
Installation 112
FUEL GAUGE SENDER 113
Removal 113
Installation 113
LOW FUEL SENDER 114
Removal 114
Installation 114
TANK BREATHER VALVE 115
Removal 115
Installation 115
Disassembly 115
Assembly 115
FUEL RECEIVER (WIGGINS QUICK FILL) 116
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL) 117
SECTION C ENGINE INDEX 119
SECTION C2 POWER MODULE INDEX 121
POWER MODULE 123
GENERAL INFORMATION 123
POWER MODULE SERVICE 124
Removal 124
Installation 128
SECTION C3 COOLING SYSTEM INDEX 131
COOLING SYSTEM 133
RADIATOR 133
Removal 133
Service 134
Installation 134
RADIATOR FILL PROCEDURE 135
RADIATOR REPAIR 135
Internal Inspection 135
External Cleaning 136
Disassembly 136
Cleaning and Inspection 137
Assembly 137
Additional Service Information 139
PRESSURE TESTING 139
COOLANT SYSTEM TROUBLESHOOTING 139
SECTION C4 POWER TRAIN INDEX 141
POWER TRAIN 143
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 143
General Information 143
Removal 143
ALTERNATOR INSTALLATION 145
Engine/Alternator Mating 145
Alternator Measurement 145
Engine End Play Measurement 146
Determining Shim Requirements 147
Installing Alternator On Engine 148
ENGINE 149
Removal 149
Installation 149
SECTION C5 AIR CLEANERS INDEX 151
AIR CLEANERS 153
Service Checks 153
Filter Element Replacement 154
Main Filter Element Cleaning 156
Precleaner Section 157
Cleaning Precleaner Tubes 157
Air Intake Troubleshooting 158
SECTION C7 FAN DRIVE CLUTCH INDEX 159
COMPONENTS 160
Input 160
Output 160
Stationary Components 161
OPERATIONAL MODES 162
Fully Engaged 162
Modulated Variable Speed 162
Fully Released 163
Lubricating and Cooling Oil 164
MAINTENANCE 165
TROUBLESHOOTING 166
Preliminary Checks 166
FIELD CHECK DIAGNOSIS 167
Preliminary Checks – Engine Off 167
Check Clutch Release 167
Check Clutch Lock-up 168
Overheating 168
Thermal Sensor and Solenoid Valve 169
On Truck Test 169
Off Truck Test 169
FAN CLUTCH DISASSEMBLY INSTRUCTIONS 174
REASSEMBLY OF THE FAN CLUTCH 181
INSPECTION OF PARTS 192
REBUILD TOOLS 196
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 197
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 199
24VDC ELECTRIC SUPPLY SYSTEM 201
ELECTRICAL SYSTEM DESCRIPTION 201
BATTERIES 201
Maintenance and Service 201
Troubleshooting 201
BATTERY CHARGING ALTERNATOR 203
24VDC ELECTRIC START SYSTEM 203
CRANKING MOTORS 203
Removal 203
Installation 204
CRANKING MOTOR TROUBLESHOOTING 204
Preliminary Inspection 205
No-Load Test 205
Interpreting Results of Tests 205
Disassembly 206
Cleaning and Inspection 206
Armature Servicing 207
Field Coil Checks 209
Field Coil Removal 209
Solenoid Checks 209
Test 209
Assembly 211
Pinion Clearance 212
MAGNETIC SWITCH 212
Coil Test 212
Electric Start System Wiring Diagrams 212
ENGINE PRELUB SYSTEM 213
OPERATION 213
Pressure Switch 213
Suction Line 213
Outlet Line 213
Check Valve 213
Solenoid Timer 213
TROUBLESHOOTING PRELUB STARTER CIRCUIT 215
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 219
24VDC ELECTRICAL SYSTEM COMPONENTS 221
PASSENGER SEAT BASE COMPARTMENT 221
COMPONENTS 221
Taillight Resistor Diode Assemblies 221
Inclinometer 221
Brake Warning Buzzer (BWB) 221
Lubrication System Timer 221
Three Minute Idle Timer Components 221
Three Minute Idle Timer 223
Idle Timer Relay 223
Three Minute Idle Contactor 223
Three Minute Idle Circuit Test 223
Data Store Button 223
Komatsu Engine Quantum Connector (Not Used) 223
Komatsu Engine Cense Connector 223
STATEX III Propulsion System Diagnostic Connector 223
Modular Mining Port (Optional) 223
Alarm Indicating Device (AID) System 224
Diode Matrix (Without Sound) 224
Diode Matrix (With Sound) 225
Hot Switch Inverter 225
Hot Switch Inverter Card (Slot 4) (Not Used) 225
Temperature 225
Oil Level 225
Temperature and Latch 225
Coolant Level/Flasher 226
Lamp Test 226
BATTERY EQUALIZER BOX 226
Troubleshooting 226
BODY-UP SWITCH 227
Adjustment 227
Service 227
HOIST LIMIT SWITCH 228
Adjustment 228
Service 228
24-VOLT RELAY AND DIODE BOARDS 228
RELAY BOARDS 229
Description 229
SERVICE 229
To Replace A Relay: 229
To Replace A Circuit Breaker: 229
To Replace A Circuit Panel Card 230
Relay Board Components 230
Installing Additional Circuits 231
DIODE BOARD 1 232
Diode Testing 232
CIRCUIT BREAKERS 234
SECTION D10 BATTERY CHARGING ALTERNATOR INDEX 235
BATTERY CHARGING SYSTEM 239
BATTERY CHARGING SYSTEM 239
ELECTRICAL SYSTEM DESCRIPTION 239
CHARGE VOLT AND AMP VALUES 239
BATTERY 239
Maintenance and Service 239
Troubleshooting 240
Undercharging 240
Overcharging 240
Corrosion 240
Acid Levels 240
Non-Use or Storage 240
Freezing 241
BATTERY CHARGING ALTERNATOR 242
GENERAL INFORMATION 242
General Description 242
Terminal Identification and Location 243
Battery Positive (B+) 243
Battery Negative (B-) 243
DC Output (D+) 243
AC Output (R) 243
Regulator Harness Plug Identification 243
Alternator Specifications 243
Performance Curve 243
Battery/Alternator Terminology 244
WIRING DIAGRAM 246
DIMENSIONS AND TORQUE VALUES 247
PERIODIC MAINTENANCE 248
TESTING 248
GENERAL INFORMATION 248
Troubleshooting Alternator (On-Truck) 248
Equipment Required 248
Preliminary Checks 248
Test Set-up 250
Test Procedure 251
REGULATOR TESTING 252
Regulator Bypass Test (No Output) 252
Regulator Bypass Test (Amp Rating) 253
BENCH TESTING 254
Equipment 254
Identification Record 254
Advanced Troubleshooting 254
Bench Test 1: No-Load Test 254
Bench Test 2: Full Load Test 255
Bench Test 3: Regulator Bypass Test 255
STATIC TESTING 256
Equipment 256
Identification Record 256
Regulator Tester 256
Check For Shorted Power Transistor 256
Circuit Tests 257
FIELD COIL TESTS 258
Field Coil Test 1: Check for Open or Shorted Field Coil 258
Field Coil Test 2: Check For Grounded Field Coil 258
STATOR TESTS 259
Stator Test 1: Check For Stator-To-Stator Continuity 259
Stator Test 2: Check For Grounded Stators 260
THERMAL SWITCH TEST 260
Initial Test 260
Verifying a Faulty Thermal Switch 261
TROUBLESHOOTING TIPS 262
ALTERNATOR 266
ALTERNATOR REPAIR 266
Removal 266
Installation 268
Special Tools and Lubricants 268
Epoxy Adhesive 269
Liquid Threadlockers 269
Elastoplastic Silicone Resin 269
ALTERNATOR EXPLODED VIEW 271
ALTERNATOR DISASSEMBLY 273
Regulator Removal 273
Fan Removal 274
Pulley Removal 275
Anti-Drive End Housing Removal 275
Anti-Drive End Rotor Removal 277
Drive End Housing Removal 279
Drive End Rotor Removal 285
Field Coil Removal 286
Drive End and/or Anti-Drive End Stator Removal 288
CLEANING AND INSPECTION 290
ALTERNATOR ASSEMBLY 290
Anti-Drive End Stator Installation 290
Drive End Stator Installation 292
Field Coil Installation 295
Drive End Bearing Installation 297
Drive End Rotor Installation 299
Rotor and Rotor Shaft Installation 299
Drive End Housing Installation 300
Anti-Drive End Rotor Installation 304
Anti-Drive End Housing Installation 305
Regulator Installation 308
THERMAL SWITCH 309
Removal 309
Installation 311
SUPPORT STAND 311
SECTION D35 PAYLOAD METER III INDEX 313
Introduction 318
Data Summary 318
Data Gathering 318
COMPONENT DESCRIPTION 319
System Diagram 319
Suspension Pressure Sensors 319
Inclinometer 319
Operator Display 319
Operator Switch 320
Speed Input 320
Body-Up Switch 320
Brake Lock Switch 320
Payload Meter 320
Communications Ports 320
Key Switch Input 321
Payload Meter Power 321
Load Lights 321
Wiring and Termination 322
TCI Outputs 322
OPERATOR’S DISPLAY AND SWITCH 323
Reading the Speedometer 323
Reading the Load Display 323
Using the Operator ID 323
Using the Load and Ton Counter 323
Total Ton Counter 323
Total Load Counter 324
Clearing the Counters 324
Viewing Live Sensor Data 324
Other Display Messages 324
PAYLOAD OPERATION & CALCULATION 325
Description of Haul Cycle States 325
Haul Cycle Description 325
Load Calculation 326
Carry Back 326
Measurement Accuracy 326
SOURCES FOR PAYLOAD ERROR 326
Payload Error 326
Loading Conditions 327
Pressure Sensors 327
Swingloads 327
Speed and Distance 327
HAUL CYCLE DATA 327
Haul Cycle Warning Flags 329
Frame Torque Data 330
Sprung Weight Data 330
Maximum Speed Data 330
Alarm Records 330
Fault Code Data 331
PC SOFTWARE OVERVIEW 332
System Configuration 332
Installing the PLMIII Software 332
DOWNLOADING DATA 333
PLM III SYSTEM CONFIGURATION 334
Starting Communications 334
Displayed Payload Units 334
Time Units 334
Connection Menu 334
Connecting to the Payload Meter 335
Configure the Payload Meter 335
Setting the Date and Time 335
Setting the Truck Type 336
Setting the Gauge Display Units 336
Setting the Frame Serial Number 336
Setting the Truck Number 336
Setting the Komatsu Distributor 336
Setting the Komatsu Customer 336
Setting the Overload Speed Limit Function 337
Clean Truck Tare 338
Inclinometer Calibration 338
DATA ANALYSIS 339
Creating a Query 339
Sorting on Truck Unit Number 339
Sorting on Truck Type 339
Sorting on Date Range 340
Sorting on Time Range 340
Payload Detail Screen 341
Creating Reports 341
Summary – one page report 342
Detailed – multi-page report 342
Creating Graphs 343
Exporting Data 343
CSV Export 343
Compressed 344
Importing Data 345
Deleting Haul Cycle Records 345
Viewing Alarms 346
Deleting Alarm Records 346
TROUBLESHOOTING SECTION 347
TROUBLESHOOTING 347
Viewing Active Alarms 347
Real-Time Data Display 347
Testing the Payload Lights 347
Creating Log Files of Inputs 348
Daily Inspections 348
Periodic Maintenance 348
Abnormal Displays at Power-Up 349
No Payload Display When Key Switch is Turned ON 350
No Display on Speedometer 351
No Display on Operator Display 351
No Communications With PC 352
Load Lights Don’t Light During Loading 353
Load Lights Remain ON 354
Load Lights Remain ON During Dumping 354
Display Doesn’t Clear When The Load Is Dumped 354
Calibration Problems 355
Alarm 1 – Left Front Pressure High 356
Alarm 2 – Left Front Pressure Low 356
Troubleshoot Wiring to Left Front Suspension 356
Alarm 3 – Right Front Pressure High 357
Alarm 4 – Right Front Pressure Low 357
Troubleshoot Wiring to Right Front Suspension 357
Alarm 5 -Left Rear Pressure High 358
Alarm 6 – Left Rear Pressure Low 358
Troubleshoot Wiring to Left Rear Suspension 358
Alarm 7 – Right Rear Pressure High 359
Alarm 8 – Right Rear Pressure Low 359
Troubleshoot Wiring to Right Rear Suspension 359
Alarm 9 – Inclinometer High 360
Alarm 10 – Inclinometer Low 360
Troubleshoot Inclinometer Wiring 360
Alarm 13 – Body Up Input Failure 361
Alarm 16 – Memory Write Failure 362
Alarm 17 – Memory Read Failure 362
Alarm 18 362
Alarm 19 362
Alarm 22 362
Operator Switch Doesn’t Work 363
Alarm 26 – User Switch Fault – SELECT 363
Alarm 27 – User Switch Fault – SET 363
Connector Map 364
Connectors 365
General Description 366
Tools Required 366
Checkout Procedure 366
PLMIII CHECKOUT PROCEDURE CONFIRMATION 370
Flashburn Programming 370
Confirmation Checklist 372
SECTION E ELECTRICAL PROPULSION INDEX 373
SECTION E2 ELECTRICAL PROPULSION COMPONENTS 375
ELECTRICAL PROPULSION COMPONENTS 379
GENERAL SYSTEM DESCRIPTION 379
CONTROL SYSTEM 379
System Operation 380
FL275 Panel 381
CARD REPLACEMENT 382
Removal 382
Installation 382
Card Repair 382
Panel Wiring 382
COMPUTER DESCRIPTION 383
Microprocessor 383
Download Capability 383
SOFTWARE 383
Base Monitor Program 383
Runtime Monitor Program – OBJ Running Code 383
Configuration Software – CFG 384
PTU – Portable Test Unit Code 384
System Regulation 384
Propulsion 385
Retarding 385
TWO-DIGIT DISPLAY PANEL 386
The Coded Number 386
Events 386
Frames 387
Windows 387
System Categories 387
Limits On Resetting Faults 387
NA Faults 388
Event Sequence 388
Resetting Events 388
Event Descriptions 388
Subcode Descriptions 388
2-DIGIT DISPLAY PANEL SUBCODES 396
PORTABLE TEST UNIT (PTU) 399
DESCRIPTION 399
Operational Hints 399
SOFTWARE INSTALLATION PREPARATION 400
HARD DISK SPACE REQUIREMENTS 400
SOFTWARE INSTALLATION ON PTU 400
PTU/Truck Communication Problems 401
THE MAIN MENU 402
Quit Menu 402
PTU Talk To Truck 402
View PTU Saved Files 402
List Stat Data Files 402
Truck Setup (CFG) 402
Select Truck Setup 402
Update CFG Version 402
Change PTU Password 402
CONFIGURATION (CFG) FILE CONVERSION 404
Conversion Procedure 404
Convert Old CFG files for New software 405
STATEX CONFIGURATION FILES 408
0) Source Directory: 408
1) Select A Truck Configuration 409
2) View Truck Configuration: Data Curves 410
3) Change/View Serial and Model Numbers 411
4) View Options 411
5) Change/View Truck Specifics 413
6) Change/View Overspeeds 415
7) Save a Truck Configuration, filename: 416
8) Save Directory: 417
CHANGE PTU PASSWORD 418
PROGRAMMING THE TRUCK 419
Connect PTU to the Truck 419
Select Configuration File 419
Activate The PTU Mode 419
Check Object Code Version 420
Download Configuration Files 421
Date And Time 422
Event Data 423
Statistical Data 425
View Counters 425
View Profiles 425
Upload Statistical Data To A File 425
Statistical Data Codes – Counters 426
STATISTICAL DATA CODES – COUNTERS 427
STATISTICAL DATA CODES – PROFILES 432
TRUCK SPECIFIC INFORMATION 436
Temporary Truck Settings 437
MISCELLANEOUS FEATURES 438
Saving Data 438
PTU Abbreviations 439
Other Menu Selections 439
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 440
ALTERNATOR 440
ELECTRIC WHEEL MOTORS 440
RETARDING GRIDS 440
ELECTRONIC ACCELERATOR AND RETARD PEDALS 440
Removal 440
Installation 440
Disassembly 441
Reassembly 441
COOLING BLOWER WARNING SYSTEM 441
Operation 441
Test 441
Removal 442
Installation 442
ELECTRICAL CONTROL CABINET 443
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 448
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 449
SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 451
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 455
GENERAL INFORMATION 455
COMMUNICATIONS PORT CHECK 456
PTU Hookup 456
4 0 SEQUENCE TESTS – (ENGINE NOT ON) 457
Preparation and Setup 457
CONTROL SYSTEM SELF-TEST 458
4 1 THROTTLE SYSTEM CHECK AND ADJUSTMENT 458
4 2 RETARD SYSTEM CHECK AND ADJUSTMENT 459
PTU Setup 459
4 3 REVERSER AND PROPULSION CONTACTORS CHECK 460
4 4 NOT USED 461
4 5 RETARD CONTACTORS OPERATION CHECK 461
4 6 GROUND FAULT SENSING CHECK 461
4 7 GROUND FAULT IN RETARD OPERATION CHECK 462
4 8 OVERRIDE OPERATION CHECK 462
4 9 ANTI-REVERSAL FUNCTION (AR) CHECK 463
4 10 OVERSPEED RETARD OPERATION CHECK 463
4 11 HOIST INTERLOCK OPERATION CHECK 464
4 12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK 464
Return to Main Menu 464
5 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 465
5 1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU 465
5 2 DIGITAL INPUT CHECKS 466
5 3 DIGITAL OUTPUT CHECKS 467
6 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 471
6 1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU 471
6 2 ANALOG INPUT CHECKS 472
6 3 FREQUENCY INPUT CHECKS 476
Return to Main Menu 477
7 0 SPEED EVENT CHECKS 477
Preparation and Setup 477
Setup PTU 477
7 1 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK 478
7 2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK 478
7 3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK 478
7 4 OTHER SPEED EVENTS CHECKS 478
Return to Main Menu 478
8 0 RETARD SPEED CONTROL SYSTEM CHECK 479
Preparation and Setup 479
Setup PTU 479
8 1 OVERSPEED PICKUP AND DROPOUT CHECK 479
8 2 RETARD POT MAXIMUM SETTING CHECK 479
8 3 RETARD POT MINIMUM SETTING CHECK 479
8 4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL 480
Return to Main Menu 480
9 0 LOAD TEST USING TRUCK RETARD GRIDS 480
Setup and Preparation 480
PTU Setup 480
9 1 LOAD TEST 481
10 0 MOTOR FIELD CURRENT CHECK IN RETARDING 481
Setup PTU 481
10 1 RETARD CHECK 482
11 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 483
11 1 BRAKE SYSTEM INTERLOCKS CHECK 483
Preparation 483
11 2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT 483
11 3 SYNC TRANSFORMER CHECKOUT 484
11 4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT 484
11 5 BATTERY BOOST ADJUSTMENT 484
11 6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST 484
11 7 MOTOR ROTATION TEST 485
11 8 GROUND FAULT CHECKS 485
12 0 MISCELLANEOUS CHARTS 486
12 1 WHEEL MOTOR GEAR RATIOS 486
12 2 MAXIMUM ALLOWABLE TRUCK SPEEDS 487
12 3 ENGINE OPTIONS 488
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX 489
SECTION G2 TIRES AND RIMS INDEX 491
GENERAL INFORMATION 493
TIRES 493
Handling Tires 493
Tire Maintenance 494
Storing Tires After Removal 494
FRONT TIRES AND RIMS 495
Removal 495
Installation 496
REAR TIRES AND RIMS 497
Removal 497
Installation 498
RIM 499
Tire Removal 499
RIM AND TIRE PREPARATION 500
LUBRICANTS 500
TIRE INSTALLATION 501
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 503
FRONT WHEEL HUB AND SPINDLE 505
WHEEL HUB AND SPINDLE ASSEMBLY 505
Removal 505
Installation 507
Disassembly 508
Cleaning and Inspection 509
Assembly 509
Wheel Bearing Adjustment (Spindle Vertical) 512
Wheel Bearing Adjustment (Tire Mounted) 513
STEERING CYLINDERS AND TIE ROD 517
Spherical Bearing Wear Limits 517
Removal 518
Installation 520
Bearing Replacement 520
TOE-IN ADJUSTMENT 521
SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX 523
PIVOT PIN 525
Removal 525
Installation 526
PIVOT EYE BEARING 526
Disassembly 526
Assembly 527
PIVOT EYE REPAIR 527
Removal 527
Disassembly 527
Bushing (New) 527
Pivot Eye Bore (New) 527
Assembly 527
Installation 528
ANTI-SWAY BAR 528
Removal 528
Installation 528
Disassembly 529
Cleaning and Inspection 529
Assembly 529
REAR AXLE HOUSING 533
REAR AXLE HOUSING 533
Removal 533
Installation 533
WHEEL MOTOR 534
Removal 534
Cleaning and Inspection 534
Installation 535
WHEEL MOTOR GEAR OIL 538
Change/Filter The Gear case Oil 538
Oil 538
Remove And Clean Magnetic Plugs 538
Flushing The Gearbox 538
Check Gear Case Oil Level 538
SECTION G5 REAR AXLE HOUSING 531
SECTION H SUSPENSIONS INDEX 539
SECTION H2 FRONT SUSPENSION INDEX 541
Removal 543
Installation 545
Angle Advance Tightening Procedure 546
Disassembly 547
Cleaning and Inspection 548
Assembly (Bearing Only) 548
Suspension Assembly (Complete) 548
SUSPENSION PRESSURE TEST 550
SECTION H3 REAR SUSPENSIONS INDEX 553
Removal 556
Installation 558
Disassembly 558
Cleaning and Inspection 559
Assembly 559
SUSPENSION PRESSURE TEST 561
SECTION H4 OILING AND CHARGING PROCEDURES INDEX 563
GENERAL 565
EQUIPMENT LIST 565
Hydrair® Charging Kit 565
Installation of Charging Kit 565
Removal of Charging Kit 566
Support Blocks For Oiling and Charging Dimensions 566
FRONT SUSPENSION 567
Front Suspension Oiling 567
Front Suspension Nitrogen Charging 568
REAR SUSPENSION 570
Rear Suspension Oiling 570
Rear Suspension Nitrogen Charging 572
SECTION J BRAKE CIRCUIT INDEX 575
SECTION J2 BRAKE CIRCUIT INDEX 577
GENERAL DESCRIPTION 579
SERVICE BRAKE CIRCUIT 579
SECONDARY BRAKING AND AUTOMATIC APPLY 581
PARKING BRAKE CIRCUIT 581
Normal Operation (key switch on, engine on) 581
BRAKE LOCK CIRCUIT 582
WARNING CIRCUIT 582
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 585
BRAKE CIRCUIT COMPONENT SERVICE 587
BRAKE VALVE 587
Rebuild Criteria 587
Removal 587
Installation 589
Disassembly 591
Cleaning and Inspection 593
ASSEMBLY 593
Actuator Base Threaded Inserts 593
Boot and Cap 593
Valve Body Seal Installation 594
Regulator Sleeve O-Ring Installation 595
Actuator Plunger O-Ring Installation 595
Assembly of Valve 595
DIFFERENTIAL PRESSURE SWITCH 596
Disassembly 597
Cleaning and Inspection 597
Assembly 597
VALVE BENCH TEST AND ADJUSTMENT 597
Test Set Up Procedure 599
Brake Valve Output Pressure Adjustment 599
Differential Pressure Switch Test 600
Final Test and Adjustment 600
Installation Of Brake Pedal Actuator Assembly to Brake Valve 601
HYDRAULIC BRAKE ACCUMULATORS 603
Brake Accumulator Bleed-Down Procedure 603
Removal 603
Installation 605
Disassembly 605
Cleaning and Inspection 607
Assembly 607
Leak Testing 610
BRAKE ACCUMULATOR CHARGING 611
Temperature During Precharge 613
ACCUMULATOR STORAGE 613
Installation 614
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 615
BRAKE CIRCUIT CHECK-OUT PROCEDURE 617
EQUIPMENT REQUIRED 620
INITIAL SYSTEM SET-UP 621
Parking Brake 621
Service Brakes 622
Brake Lock/Secondary 622
Low Brake Pressure and Auto Apply 623
Reapplications 623
Differential Pressure Switch 623
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 625
The Brakes are Locked, Service, and/or Parking 625
Both Brake Circuits are Dragging 625
One Brake Circuit is Dragging 625
Brakes are Not Going to Full Pressure 625
A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off 625
Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released 626
Differential Pressure Warning Circuit is Not Operating 626
A Low Brake Pressure Warning Occurs When Brakes are Applied 626
Low Pressure Warning Circuit Not Operating Properly 626
Low Pressure Warning is On Even Though System Pressure is Correct 627
Low Pressure Warning Comes On and Pressure is Low 627
A Squeal is Heard When Controller is Operated 627
Output Pressure At Controller is Correct but Brakes are Not Applying 627
Brake Pressures Drift Excessively While Pedal is Held Steady 627
Oil is Leaking Around the Pedal Base 627
Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM 627
CHECK-OUT PROCEDURE 628
HYDRAULIC BRAKE SYSTEM DATA SHEET 628
SECTION J5 FRONT DISC BRAKES INDEX 631
BRAKE CALIPER 633
Removal 633
Installation 634
Disassembly 635
Cleaning and Inspection 635
Assembly 637
BRAKE LINING 637
Replacement 637
FRONT SERVICE BRAKE BURNISHING 639
BRAKE BLEEDING PROCEDURE 640
REAR DISC BRAKES 643
REAR BRAKES 643
CALIPER, DISC, AND PARKING BRAKE 643
Removal 643
Installation 644
CALIPER PISTON 646
Piston Assembly Removal 646
Inspection 646
Piston Assembly Installation 647
FUNCTIONAL TEST OF PISTON ASSEMBLY 648
Return Spring Force 648
Built-In Clearance 648
Grip Force 650
Grip Force Measurement 651
Spring Force Measurement 653
Disassembly of Piston Assembly 654
Assembly of Piston Assembly 655
BENCH TEST 655
BRAKE LINING 656
Replacement 656
SERVICE BRAKE BURNISHING 659
SAFETY PRECAUTIONS 659
Rear Brake Burnishing 660
BRAKE BLEEDING PROCEDURE 661
Spring Force Measurement 662
SECTION J6 REAR BRAKES INDEX 641
SECTION J7 PARKING BRAKE INDEX 663
GENERAL INFORMATION 665
PARKING BRAKE CALIPER 665
Lining Thickness Inspection 665
Removal 666
Installation 666
Parking Brake Adjustment 667
Parking Brake Caliper Disassembly 668
Cleaning and Inspection 669
Parking Brake Caliper Assembly 670
PARKING BRAKE LINING REPLACEMENT 670
PARKING BRAKE BURNISH PROCEDURE 670
Lining Conditioning 670
BRAKE BLEEDING PROCEDURE 671
SECTION L HYDRAULIC SYSTEM INDEX 673
SECTION L2 HYDRAULIC SYSTEM OVERVIEW 675
HYDRAULIC SYSTEM OVERVIEW 676
Hoist Circuit Operation 676
Steering, Brake and Pantograph Circuit Operation 676
Axle Blower System Operation 676
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 679
HYDRAULIC SYSTEM COMPONENT REPAIR 681
HOIST PUMP 681
Removal 681
Installation 683
Disassembly 683
Inspection 686
Assembly 687
PISTON PUMP 692
Removal 692
Installation 693
Disassembly 695
Inspection of Parts 701
Assembly 703
AXLE BLOWER HYDRAULIC MOTOR 708
Removal 708
Installation 708
Rear Axle Blower Housing 708
Disassembly 708
Assembly 709
Disassembly 711
Inspection 713
Assembly 714
Trouble Shooting 715
Hand Wheel Control 716
Disassembly 716
Assembly 716
HYDRAULIC TANK 718
Filling Instructions 718
Removal 719
Installation 719
HYDRAULIC TANK STRAINER AND DIFFUSER 720
Removal 720
Inspect and Clean 721
Installation 721
SECTION L4 STEERING CIRCUIT INDEX 723
STEERING CIRCUIT OPERATION 725
COMPONENT DESCRIPTION 726
Steering Control Valve 726
Unloader Valve 727
Bleed-Down Manifold Valve 727
Flow Amplifier 732
FLOW AMPLIFIER SYSTEM OPERATION 733
No Steer 733
Steering Left 735
Steering Right 737
No Steer, External Shock Load 739
Steering Pump 741
High Pressure Filter 741
Accumulators 741
Low Precharge Warning Switch 741
SECTION L5 STEERING CONTROL VALVE INDEX 743
Removal 745
Installation 746
STEERING CONTROL VALVE REBUILD 747
Disassembly 747
Cleaning and Inspection 748
Assembly 748
BRAKE / STEERING PUMP 752
Removal 752
Installation 754
Disassembly 755
Inspection of Parts 755
Assembly 757
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 759
STEERING CIRCUIT COMPONENT REPAIR 761
BLEED-DOWN MANIFOLD 761
Removal 761
Installation 761
ACCUMULATOR 762
Removal 762
Installation 763
Disassembly 764
Cleaning and Inspection 764
Assembly 765
Leak Testing 766
STEERING ACCUMULATOR CHARGING 767
Temperature During Precharge 770
ACCUMULATOR STORAGE 771
Installation 771
FLOW AMPLIFIER 772
Removal 772
Installation 772
Disassembly 773
Assembly 776
STEERING CYLINDERS 777
Disassembly 777
Piston Seal and Bearing Installation 777
Cylinder Assembly 777
Test 777
TROUBLESHOOTING CHART 780
SECTION L7 HOIST CIRCUIT INDEX 785
HOIST CIRCUIT OPERATION 787
COMPONENT DESCRIPTION 788
Hydraulic Tank 788
Hydraulic Pump 788
High Pressure Filter 788
Hoist Valve 788
Hoist Pilot Valve 789
Bleed-Down Manifold 790
Counterbalance Manifold 790
Hoist-Up Limit Solenoid 790
Pilot Operated Check Valve 790
HOIST VALVE OPERATION 792
Float Operation 792
Power Up Operation (Figure 7-6) 794
Hold Operation (Figure 7-7) 796
Power Down Operation (Figure 7-8) 798
Float Operation (Figure 7-9) 800
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 803
HOIST VALVE 805
Removal 805
Installation 805
O-Ring Replacement 807
INLET SECTION 808
Disassembly 808
Cleaning and Inspection 809
Assembly 809
REAR SPOOL SECTION (WORK PORTS) 810
Disassembly 810
Cleaning and Inspection 812
Assembly 812
HOIST PILOT VALVE 814
Removal 814
Installation 814
Disassembly 815
Cleaning and Inspection 816
Assembly 816
HOIST UP LIMIT SOLENOID VALVE 817
HOIST CYLINDERS 818
Removal 818
Installation 819
Disassembly 821
Cleaning and Inspection 822
SS1143 Tightening Tool – Assembly Drawing 823
ASSEMBLY OF QUILL AND CYLINDER 823
Quill Installation 823
Installation Of Check Balls And Plugs In Quill 824
Assembly of Cylinder 826
Pressure Testing 827
COUNTERBALANCE MANIFOLD 827
SECTION L9 HIGH PRESSURE FILTERS INDEX 829
HOIST CIRCUIT FILTER 831
Filter Element Replacement 831
Removal 832
Installation 832
Indicator Switch 832
STEERING CIRCUIT FILTER 833
Filter Element Replacement 833
Removal 834
Installation 834
Indicator Switch 834
INDICATOR SWITCH 834
Test Procedure 834
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE 837
HYDRAULIC CHECKOUT PROCEDURE 839
Initial Start Up and Flushing (Steps 5 – 22) 840
Component Checkout and Adjustment (Steps 23 – 34) 842
Adjustment Procedure for Hoist Counterbalance Cartridge Valve (Steps 34a-34l) 844
Counterbalance Valve Adjustment (Steps f & g): 846
Manifold reassembly (steps i through k): 846
Piston Pump and Axle Box Hydraulic Motor Adjustment (Steps 35 – 50) 846
Oil Cleanliness Check 847
Oil Sampling Location on Truck: 847
Oil Sampling Process and Cleanliness Criteria: 847
DISABLED TRUCK DUMPING PROCEDURE 848
HOOKUP 848
DUMPING PROCEDURE 848
Raising the Body: 848
Lowering the Body: 849
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 857
SECTION M4 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM INDEX 859
SYSTEM ADJUSTMENT 861
PUMP 864
Removal 864
Disassembly 864
Inspection 864
Assembly 864
Installation 864
BLOWER DRIVE MOTOR 867
Removal 867
Disassembly 867
Inspection Of Parts 868
Assembly 869
Installation 870
BLOWER BEARING REPAIR 870
Removal 870
Replacement 870
Assembly 871
AIR CLEANER 871
Assembly 871
Removal 871
Assembly 871
SECTION M7 HEATER OPTIONS INDEX 873
GENERAL INFORMATION 875
TROUBLESHOOTING 875
HEATER ELEMENT 875
Removal 875
Installation 876
GENERAL 877
Maintenance 877
HEATING ELEMENT 877
Removal 877
Installation 878
THERMOSTAT 878
Removal 878
Installation 878
GENERAL INFORMATION 879
TROUBLESHOOTING 879
HEATER ELEMENT 879
Removal 879
Installation 880
SECTION M8 SPECIAL TOOLS 881
NITROGEN CHARGING VALVE 881
ROLL-OUT ASSEMBLY 881
EYE BOLT 881
OFFSET WRENCH 882
TORQUE ADAPTER 882
HANDLE 882
SEAL INSTALLER 882
SLEEVE ALIGNMENT TOOLS 883
QUICK DISCONNECT COUPLING 883
HARNESS 883
SEAL INSTALLATION RING 883
BELT TENSION TESTER 884
BELT ALIGNMENT TOOL 884
SOCKETS AND ADAPTERS 884
DUST CAPS 884
HYDRAULIC SYSTEM FLUSHING TOOLS 885
PAYLOAD DATA MANAGER 885
HYDRAULIC SYSTEM VACUUM PUMP 885
MISCELLANEOUS SERVICE TOOLS 886
BRAKE PISTON TOOL 887
HIGH VOLTAGE TOOLS 890
2000 VDC METER 890
GROUNDING STICKS 890
BODY PAD SPACER TOOL 891
SECTION M19 RADIATOR SHUTTERS INDEX 893
SECTION N OPERATOR’S CAB INDEX 903
SECTION N2 TRUCK CAB INDEX 905
TRUCK CAB 907
TRUCK CAB 907
Description 907
Removal 908
Installation 910
CAB DOOR 910
Removal 910
Installation 911
Door Adjustment 911
Door Jam Bolt Adjustment 911
Door Handle Plunger Adjustment 913
Replace Door Glass 914
Replace Door Window Regulator 918
Replace Door Handle or Latch Assembly 918
Door and Door Hinge Seal Replacement 919
Door Opening Seal Removal 919
Installation 919
GLASS REPLACEMENT 920
Adhesive-Bonded Windows 920
Recommended Tools/Supplies 920
Replacement Procedure 920
Windshield and Rear Glass 921
Removal 921
Installation 922
Removal and Installation of Operator Seat 923
Inspection 923
Removal 923
Installation 923
Removal and Installation of Passenger Seat 924
Removal 924
Installation 924
SECTION N3 CAB COMPONENTS INDEX 925
WINDSHIELD WIPERS 927
WIPER MOTOR REPLACEMENT 927
Removal 927
Installation 927
WIPER ARM REPLACEMENT 927
Removal 927
Installation 928
WIPER LINKAGE REPLACEMENT 928
Removal 928
Installation 929
WINDSHIELD WASHER 929
Operation 929
Service 929
SEAT BELT 930
Removal 930
Installation 930
SECTION N4 OPERATOR COMFORT INDEX 933
HEATER/AIR CONDITIONER 937
CONTROLS 937
Operation 937
Heater/Air Conditioner Vents 937
Defroster Vent Control Switch 937
Heat Control Switch 937
Temperature Control Knob 937
Fan Control Knob 937
Heater/Air Conditioner Selector Switch 937
COMPONENTS 938
Circuit Breakers 938
Relays 938
Heater Core 938
Fan Motor and Speed Control 939
Test 939
Actuators 939
Test 939
Cab Air Filter 940
AIR CONDITIONING SYSTEM 942
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 943
PRINCIPLES OF REFRIGERATION 943
Air Conditioning 943
Refrigeration – The Act of Cooling 944
The Refrigeration Cycle 944
AIR CONDITIONER SYSTEM COMPONENTS 945
Compressor (Refrigerant Pump) 945
Service Valves 945
Receiver-Drier 945
Condenser 945
Expansion Block Valve 946
Accumulator 946
Evaporator 947
ELECTRICAL CIRCUIT 947
Thermostat 947
Compressor Clutch 948
Trinary™ Switch 948
SYSTEM SERVICING 950
SERVICE TOOLS AND EQUIPMENT 951
Recovery/Recycle Station 951
Leak Detector 952
Service Valves 952
Vacuum Pump 952
Manifold Gauge Set 953
Low Side Gauge 953
High Side Gauge 953
Installing Manifold Gauge Set 954
Purging Air From Service Hoses 954
SYSTEM PERFORMANCE TEST 955
SYSTEM OIL 956
Handling and Reusing RPAG Oil 956
Oil Quantity 956
Checking System Oil 956
REFRIGERANT 957
Recycled Refrigerant 957
Reclaimed Refrigerant 957
Refrigerant Quantity 958
R-134a Refrigerant Containers 958
SYSTEM LEAK TESTING 958
Electronic Leak Detector 959
Tracer Dyes 959
Soap and Water 959
RECOVERING AND RECYCLING THE REFRIGERANT 959
Performing the Recovery Cycle 959
Performing the Recycling Procedure 960
Evacuating and Charging the A/C System 960
SYSTEM REPAIR 960
System Flushing 961
COMPONENT REPLACEMENT 961
Hoses and Fittings 961
Lines 961
Expansion Valve 962
Receiver-Drier 962
Thermostat 962
Compressor 962
Accumulator 963
Clutch 963
Servicing the Compressor Clutch 964
Pulley Removal 966
Clutch Coil Check 966
Pulley Installation 967
Clutch Assembly Installation 967
EVACUATING THE SYSTEM 968
CHARGING THE A/C SYSTEM 970
AIR CONDITIONER DRIVE BELT 970
Pulley Alignment 970
Belt Tension 971
TROUBLESHOOTING 972
Preliminary Checks 972
Diagnosis of Gauge Readings and System Performance 973
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 974
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 980
SECTION N5 OPERATOR CONTROLS 981
OPERATOR CONTROLS 983
STEERING WHEEL AND CONTROLS 984
STEERING WHEEL 984
HORN BUTTON 984
TILT/TELESCOPE LEVER 984
MULTI-FUNCTION TURN SIGNAL SWITCH 984
Turn Signal Operation 985
High Beam Headlight Operation 985
Windshield Wiper Operation 985
STEERING COLUMN 985
Removal 985
Inspection 986
Installation 986
PEDALS 986
SERVICE BRAKE PEDAL 986
DYNAMIC RETARDER PEDAL 987
Optional – Dual Function/Single Pedal 987
THROTTLE PEDAL 987
OVERHEAD PANEL CONTROLS AND COMPONENTS 988
GRADE/SPEED WARNING CHART 988
RADIO SPEAKERS 988
WINDSHIELD WIPERS 988
WARNING ALARM BUZZER 988
CAB RADIO 988
WARNING LIGHTS DIMMER CONTROL 988
WARNING/STATUS INDICATOR LIGHT PANEL 988
AIR CLEANER VACUUM GAUGES 988
CENTER CONSOLE 989
TRUCK CONTROLS 990
F-N-R Selector Switch 990
Hoist Control Lever 990
Trolley Master Control Lever 990
CONSOLE SWITCHES AND CONTROLS 990
Cigarette Lighter 990
Window Control Switches 990
Engine Shutdown Switch 990
Override Switch 991
Retard Speed Control (RSC) Switch 991
Retard Speed Control (RSC) Dial 991
Statex III Download Port 992
Engine Diagnostic Port (CENSE) 992
Engine Diagnostic Connectors 992
Data Storage Button 992
Passenger Seat 992
PAYLOAD METER 993
Payload Meter Download Connector 993
CAB CLIMATE CONTROL 994
HEATER/AIR CONDITIONER VENTS 994
HEATER/AIR CONDITIONER CONTROLS AND VENTS 994
Defroster Vent Control Switch 994
Heat Control Switch 994
Temperature Control Knob 994
Fan Control Knob 994
Heater/Air Conditioner Vents 994
OPERATOR SEAT 995
ADJUSTMENT 995
INSTRUMENT PANEL 996
GENERAL INFORMATION 996
CONTROL SYMBOLS 996
CONTROL SWITCHES AND GAUGES 997
Key Switch 998
Engine Shutdown Switch With Timer Delay 998
Fog Light Switch 998
Ladder Light Switch 998
Backup Light Switch 998
Panel Illumination Lights 998
Cab Air Conditioner/Heater Vents 998
Engine Cold Weather Starting Aid Switch 998
Rotating Beacon Light Switch 999
Heated Mirror Switch 999
Wheel Brake Lock Switch 999
Leakage Test Switch (Trolley Only) 999
Parking Brake Switch 999
Digital Tachometer 999
Right Turn Signal Indicator Light 1000
High Beam Headlight Indicator Light 1000
Left Turn Signal Indicator Light 1000
Digital Speedometer/Payload Meter Display 1000
Voltmeter Gauge 1000
Engine Oil Pressure Gauge 1000
Engine Water Temperature Gauge 1000
Fuel Gauge 1000
Engine Hourmeter 1001
Headlight Switch 1001
Panel Illumination Lights Dimmer Rheostat 1001
Payload Meter Switch 1001
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL 1002
INDICATOR LIGHT FUNCTIONS 1003
High Hydraulic Oil Temperature 1003
Low Steering Pressure 1003
Low Accumulator Precharge Pressure Warning 1003
Electric System Fault Warning 1004
Low Brake Pressure Indicator 1004
Low Hydraulic Tank Level 1004
Low Automatic Lubrication System Pressure 1004
Circuit Breaker Tripped 1004
Hydraulic Oil Filter 1004
Low Fuel Indicator 1005
Parking Brake Indicator 1005
Service Brake Indicator 1005
Body Up Indicator 1005
Dynamic Retarding Indicator 1005
Stop Engine Warning 1005
Backup Indicator 1005
Engine Shutdown Timer Switch- Five Minute Idle 1005
Retard Speed Control 1005
Service Engine Indicator (AEM) 1006
High Wheel Motor Temperature Indicator 1006
Blower Fault Warning 1006
Service Engine Indicator (CENSE) 1006
Komatsu Engines w/Centry™ Fuel Control 1006
Hazard Warning Light Switch 1006
Lamp Test Switch/Centry™ Diagnostic Test Switch 1006
Backup Lights 1010
Retard Lights 1010
Brake Light 1010
Backup Alarm 1010
CENTRY™ FUEL SYSTEM DIAGNOSTICS 1011
GENERAL OPERATION 1011
DETERMINING FAULT CODES 1011
EXITING THE DIAGNOSTICS MODE 1012
SECTION P LUBRICATION AND SERVICE INDEX 1013
SECTION P2 LUBRICATION AND SERVICE INDEX 1015
LUBRICATION AND SERVICE 1017
GENERAL INFORMATION 1017
HYDRAULIC TANK SERVICE 1017
Adding Oil 1017
COOLING SYSTEM 1018
Radiator Filling Procedure 1018
RESERVE ENGINE OIL SYSTEM – (OPTIONAL) 1018
Reserve Oil Tank Filling Procedure (Remote Fill) 1018
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS 1020
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued) 1021
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1022
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1022
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1023
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 1024
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1025
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 1026
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1027
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1028
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1028
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1029
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1030
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1031
AUTOMATIC LUBRICATION SYSTEM 1033
GENERAL DESCRIPTION 1033
SYSTEM COMPONENTS 1034
Filter Assembly 1034
Hydraulic Motor and Grease Pump 1034
Reservoir 1034
Fixed Pressure Reducing Valve 1034
Flow Control Valve 1034
Solenoid Valve 1035
Vent Valve 1035
24VDC Lubrication Cycle Timer 1035
Time Delay Module 1035
Pump Cutoff Pressure Switch 1035
Unloader Valve 1035
Pressure Switch 1035
Pressure Gauge 1035
Manual Override Button 1035
Injectors 1035
SYSTEM OPERATION 1038
Normal Operation 1038
Pressure Failure Detection Circuits 1039
GENERAL INSTRUCTIONS 1040
LUBRICANT REQUIRED FOR SYSTEM 1040
SYSTEM PRIMING 1040
LUBRICANT PUMP 1041
Pump Housing Oil Level 1041
Pump Pressure Control 1041
FILTER AND RESERVOIR 1041
Filter Assembly Element 1042
INJECTORS (SL-1 Series H) 1042
Injector Specifications 1042
Injector Adjustment 1042
INJECTOR OPERATION 1044
SYSTEM CHECKOUT 1045
Lubrication Cycle Timer Check 1045
Lubrication Cycle Timer Adjustment 1046
PREVENTIVE MAINTENANCE INSPECTION 1046
10 Hour Lubrication System Inspection 1046
100 Hour Inspection 1046
250 Hour Inspection 1046
500 Hour Inspection 1047
1000 Hour Inspection 1047
PUMP REBUILD 1048
Disassembly 1048
Cleaning and Inspection 1048
Assembly 1050
VENT VALVE REBUILD 1051
Disassembly and Assembly 1051
SYSTEM TROUBLESHOOTING CHART 1052
SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX 1055
SECTION R SYSTEM SCHEMATICS 1061
EF5755 BRAKE SCHEMATIC 1063
EJ2730 HYDRAULIC SCHEMATIC 1064
XS1000 ELECTRICAL SCHEMATIC 1065

DESCRIPTION:

Komatsu 730E Trolley Dump Truck Shop Manual CEBM026100  – PDF DOWNLOAD

• SERIAL NUMBERS
  A30431, A30432, A30460,
  A30461, A30463, A30464, &
  A30467 – A30469

• FOREWORD
  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

G.B  21/12/24