Komatsu 730E Trolley Dump Truck Shop Manual CEBM026200 PDF

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Komatsu 730E Trolley Dump Truck Shop Manual CEBM026200 – PDF DOWNLOAD

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Komatsu 730E Trolley Dump Truck Shop Manual CEBM026200 – PDF DOWNLOAD 

Language : English
Pages : 1032
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 730E Trolley Dump Truck Shop Manual CEBM026200 – PDF DOWNLOAD 

SERIAL NUMBERS A30489 & A30490

FOREWORD:

• 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.
• To determine allowable payload, fill all lubricants and fuel tank to the proper level. Weigh the truck and record this value. Subtract it from the GVW to determine the allowable payload.

TABLE OF CONTENTS:

Komatsu 730E Trolley Dump Truck Shop Manual CEBM026200 – PDF DOWNLOAD 

SERIAL NUMBERS A30489 & A30490

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
SPECIFICATIONS 13
Komatsu SSA16V159 13
SECTION A3 GENERAL SAFETY AND OPERATION INDEX 15
GENERAL SAFETY AND OPERATION 18
PERSONAL SAFETY 18
Safety Rules 18
Truck Safety Features 18
Clothing And Personal Items 18
Unauthorized Modification 18
Leaving The Operator’s Seat 18
Mounting And Dismounting 19
Fire Extinguishers And First Aid Kits 19
Precautions For High Temperature Fluids 19
Asbestos Dust Hazard Prevention 20
Fire Prevention For Fuel And Oil 20
ROPS Precautions 20
Preventing Injury From Work Equipment 20
Precautions For Optional Attachments 20
Precautions When Starting The Machine 21
PRECAUTIONS FOR TRUCK OPERATION 21
Safety Is Thinking Ahead 21
Safety At The Work Site 21
Fire Prevention 21
Preparing For Operation 21
Ventilation For Enclosed Areas 21
Mirrors, Windows, And Lights 22
In The Operator’s Cab – Before Starting The Engine 22
Seat Belts 22
OPERATING THE MACHINE 22
Starting The Engine 22
Truck Operation – General 23
Traveling In The Truck 23
Precautions When Traveling In Reverse 23
Traveling On Slopes 24
Ensuring Good Visibility 24
Operating On Snow 24
Avoid Damage To The Dump Body 24
Driving Near High-Voltage Cables 24
When Loading The Truck 24
When Dumping 24
Working On Loose Ground 25
Parking The Machine 25
TOWING 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump-Starting With Booster Cables 26
Jump Starting With Receptacles 26
PRECAUTIONS FOR MAINTENANCE 27
BEFORE PERFORMING MAINTENANCE 27
Stopping The Engine Before Service 27
Warning Tag 27
Proper Tools 27
Securing The Dump Body 27
DURING MAINTENANCE 28
Personnel 28
Attachments 28
Working Under The Machine 28
Keeping The Machine Clean 28
Rules To Follow When Adding Fuel Or Oil 28
Radiator Coolant Level 28
Use Of Lighting 28
Precautions With The Battery 29
Handling High-Pressure Hoses 29
Precautions With High-Pressure Oil 29
Maintenance Near High Temperatures And High Pressures 29
Rotating Fan And Belts 29
Waste Materials 29
Use of Tie-Off Anchor During Maintenance and Repair 29
TIRES 30
Handling Tires 30
Tire Maintenance 31
Storing Tires After Removal 31
ADDITIONAL JOB SITE RULES 32
WHEN REPAIRS ARE NECESSARY 33
OPERATING INSTRUCTIONS 34
PREPARING FOR OPERATION 34
SAFETY IS THINKING AHEAD 34
WALK AROUND INSPECTION 34
ENGINE START-UP 38
AFTER ENGINE HAS STARTED 39
EMERGENCY STEERING SYSTEM 40
Operation 40
Pre-Operation Testing 40
Additional Guidelines 41
MACHINE OPERATION SAFETY PRECAUTIONS 41
LOADING 42
HAULING 42
PASSING 43
DUMPING 43
To Raise The Dump Body: 43
To Lower The Dump Body: (When dumping over a berm or into a crusher): 44
To Lower The Dump Body (When dumping on flat ground): 44
TOWING 45
Towing Procedure 45
SAFE PARKING PROCEDURES 46
ENGINE SHUTDOWN PROCEDURE 46
DELAYED ENGINE SHUTDOWN PROCEDURE 46
SUDDEN LOSS OF POWER 47
TROLLEY OPERATING INSTRUCTIONS 48
AFTER THE ENGINE HAS STARTED 48
OPERATING IN DIESEL MODE 48
OPERATING IN TROLLEY LINE MODE 49
GETTING ON LINE 49
Operating On Trolley 51
GETTING OFF LINE 52
LINE STATUS SIGNALS 52
LINE STATUS SIGNAL MARKINGS 53
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION 53
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK 54
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS 54
TRUCK FAILURE WHILE ON TROLLEY 54
SECTION A4 WARNINGS AND CAUTIONS 55
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 65
SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX 75
SHORT TERM IDLE PERIODS 77
PREPARATION FOR STORAGE 78
REMOVAL FROM STORAGE 79
RECONDITIONING AN IDLE VEHICLE 80
ENGINE OPERATION 83
After The Engine Has Started 83
ENGINE STORAGE 84
Temporary Storage (30 Days Or Less) 84
Extended Storage (More Than 30 Days) 85
RESTORING AN ENGINE AFTER EXTENDED STORAGE 86
ELECTRIC DRIVE TRUCKS 87
Storing A Truck That Is Operational 87
Storing A Truck That Is Not Operational 88
Storing A Major Component 89
Periodic Inspections 89
Placing Equipment Into Service After Storage 89
SECTION B STRUCTURES INDEX 91
SECTION B2 STRUCTURAL COMPONENTS INDEX 93
STRUCTURAL COMPONENTS 95
LADDERS 95
Removal 95
Installation 95
GRILLE AND HOOD 96
Removal 96
Installation 96
RIGHT-HAND DECK 96
Removal 96
Installation 98
CENTER DECK 98
LEFT-HAND DECK 99
Removal 99
Installation 99
SECTION B3 DUMP BODY INDEX 101
DUMP BODY 103
Removal 103
Installation 104
BODY SLING 104
BODY PADS 105
BODY GUIDE 105
Adjustment 105
BODY POSITION INDICATOR 106
HOIST LIMIT SWITCH 106
ROCK EJECTORS 106
Inspection 106
SECTION B4 FUEL TANK INDEX 107
FUEL TANK 109
Removal 109
Repair 109
Cleaning 109
Installation 110
FUEL GAUGE SENDER 111
Removal 111
Installation 111
LOW FUEL SENDER 112
Removal 112
Installation 112
TANK BREATHER VALVE 113
Removal 113
Installation 113
Disassembly 113
Assembly 113
FUEL RECEIVER (WIGGINS QUICK FILL) 114
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL) 115
SECTION C ENGINE INDEX 117
SECTION C2 POWER MODULE INDEX 119
POWER MODULE 121
GENERAL INFORMATION 121
POWER MODULE SERVICE 122
Removal 122
Installation 126
SECTION C3 COOLING SYSTEM INDEX 129
COOLING SYSTEM 131
RADIATOR 131
Removal 131
Service 132
Installation 132
RADIATOR FILL PROCEDURE 133
RADIATOR REPAIR 133
Internal Inspection 133
External Cleaning 134
Disassembly 134
Cleaning and Inspection 135
Assembly 135
Additional Service Information 137
PRESSURE TESTING 137
COOLANT SYSTEM TROUBLESHOOTING 137
SECTION C4 POWER TRAIN INDEX 139
POWER TRAIN 141
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 141
General Information 141
Removal 141
ALTERNATOR INSTALLATION 143
Engine/Alternator Mating 143
Alternator Measurement 143
Engine End Play Measurement 144
Determining Shim Requirements 145
Installing Alternator On Engine 146
ENGINE 147
Removal 147
Installation 147
SECTION C5 AIR CLEANERS INDEX 149
OPERATION 151
SERVICING THE AIR CLEANERS 151
Replacing The Elements 152
AIR CLEANER ASSEMBLY CLEANING 153
Primary Element Cleaning 153
Precleaner Section Cleaning 155
AIR INTAKE TROUBLESHOOTING 156
SECTION C7 FAN DRIVE CLUTCH INDEX 157
COMPONENTS 158
Input 158
Output 158
Stationary Components 159
OPERATIONAL MODES 160
Fully Engaged 160
Modulated Variable Speed 160
Fully Released 161
Lubricating and Cooling Oil 162
MAINTENANCE 163
TROUBLESHOOTING 164
Preliminary Checks 164
FIELD CHECK DIAGNOSIS 165
Preliminary Checks – Engine Off 165
Check Clutch Release 165
Check Clutch Lock-up 166
Overheating 166
Thermal Sensor and Solenoid Valve 167
On Truck Test 167
Off Truck Test 167
FAN CLUTCH DISASSEMBLY INSTRUCTIONS 172
REASSEMBLY OF THE FAN CLUTCH 179
INSPECTION OF PARTS 190
REBUILD TOOLS 194
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 195
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 197
ELECTRICAL SYSTEM DESCRIPTION 199
BATTERIES 199
Maintenance and Service 199
Troubleshooting 199
BATTERY CHARGING ALTERNATOR 201
24VDC ELECTRIC START SYSTEM 201
CRANKING MOTORS 201
Removal 201
Installation 202
CRANKING MOTOR TROUBLESHOOTING 202
Preliminary Inspection 203
No-Load Test 203
Interpreting Results of Tests 203
Disassembly 204
Cleaning and Inspection 204
Armature Servicing 205
Field Coil Checks 207
Field Coil Removal 207
Solenoid Checks 207
Test 207
Assembly 209
Pinion Clearance 210
MAGNETIC SWITCH 210
Coil Test 210
Electric Start System Wiring Diagrams 210
ENGINE PRELUB SYSTEM 211
OPERATION 211
Pressure Switch 211
Suction Line 211
Outlet Line 211
Check Valve 211
Solenoid Timer 211
TROUBLESHOOTING PRELUB STARTER CIRCUIT 213
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 217
PASSENGER SEAT BASE COMPARTMENT 219
COMPONENTS 219
Taillight Resistor Diode Assemblies 219
Inclinometer 219
Lubrication System Timer 219
Three Minute Idle Timer Components 219
Three Minute Idle Timer 221
Idle Timer Relay 221
Three Minute Idle Contactor 221
Three Minute Idle Circuit Test 221
Data Store Button 221
Komatsu Engine Diagnostic Connector (Centry) 221
Komatsu Engine Diagnostic Port (CENSE) 221
STATEX III Propulsion System Diagnostic Connector 221
Modular Mining Port (Optional) 221
Alarm Indicating Device (AID) System 222
Diode Matrix (Without Sound) 222
Diode Matrix (With Sound) 223
Hot Switch Inverter 223
Hot Switch Inverter Card (Slot 4) (Not Used) 223
Temperature 223
Oil Level 223
Temperature and Latch 223
Coolant Level/Flasher 224
Lamp Test 224
BATTERY EQUALIZER BOX 224
Troubleshooting 224
BODY POSITION SWITCHES 226
Proximity Switch Operation 226
Body-Up Switch Adjustment 227
Hoist Limit Switch Adjustment 227
24-VOLT RELAY AND DIODE BOARDS 229
RELAY BOARDS 230
Description 230
SERVICE 230
To Replace A Relay: 230
To Replace A Circuit Breaker: 230
To Replace A Circuit Panel Card 231
Relay Board Components 231
Installing Additional Circuits 232
DIODE BOARD 1 233
Diode Testing 233
CIRCUIT BREAKERS 235
SECTION D10 CHARGING SYSTEM INDEX 237
CHARGING SYSTEM DESCRIPTION 239
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION 239
Excessive heat 239
Dirt and dust 239
Vibration 239
PREVENTIVE MAINTENANCE PROCEDURES 240
Alternator Cleanliness 240
Alternator Mounting 240
Belt Tension And Condition 240
TROUBLESHOOTING PROCEDURES 240
ALTERNATOR PERFORMANCE TEST 240
ALTERNATOR PERFORMANCE TEST – LOAD APPLIED 241
ALTERNATOR CABLE TEST 241
VOLTAGE REGULATOR ADJUSTMENT 242
ALTERNATOR 243
Removal 243
Installation 244
SECTION D35 PAYLOAD METER III INDEX 247
Introduction 252
Data Summary 252
Data Gathering 252
COMPONENT DESCRIPTION 253
System Diagram 253
Suspension Pressure Sensors 253
Inclinometer 253
Operator Display 253
Operator Switch 254
Speed Input 254
Body-Up Switch 254
Brake Lock Switch 254
Payload Meter 254
Communications Ports 254
Key Switch Input 255
Payload Meter Power 255
Load Lights 255
Wiring and Termination 256
TCI Outputs 256
OPERATOR’S DISPLAY AND SWITCH 257
Reading the Speedometer 257
Reading the Load Display 257
Using the Operator ID 257
Using the Load and Ton Counter 257
Total Ton Counter 257
Total Load Counter 258
Clearing the Counters 258
Viewing Live Sensor Data 258
Other Display Messages 258
PAYLOAD OPERATION & CALCULATION 259
Description of Haul Cycle States 259
Haul Cycle Description 259
Load Calculation 260
Carry Back 260
Measurement Accuracy 260
SOURCES FOR PAYLOAD ERROR 260
Payload Error 260
Loading Conditions 261
Pressure Sensors 261
Swingloads 261
Speed and Distance 261
HAUL CYCLE DATA 261
Haul Cycle Warning Flags 263
Frame Torque Data 264
Sprung Weight Data 264
Maximum Speed Data 264
Alarm Records 264
Fault Code Data 265
PC SOFTWARE OVERVIEW 266
System Configuration 266
Installing the PLMIII Software 266
DOWNLOADING DATA 267
PLM III SYSTEM CONFIGURATION 268
Starting Communications 268
Displayed Payload Units 268
Time Units 268
Connection Menu 268
Connecting to the Payload Meter 269
Configure the Payload Meter 269
Setting the Date and Time 269
Setting the Truck Type 270
Setting the Gauge Display Units 270
Setting the Frame Serial Number 270
Setting the Truck Number 270
Setting the Komatsu Distributor 270
Setting the Komatsu Customer 270
Setting the Overload Speed Limit Function 271
Clean Truck Tare 272
Inclinometer Calibration 272
DATA ANALYSIS 273
Creating a Query 273
Sorting on Truck Unit Number 273
Sorting on Truck Type 273
Sorting on Date Range 274
Sorting on Time Range 274
Payload Detail Screen 275
Creating Reports 275
Summary – one page report 276
Detailed – multi-page report 276
Creating Graphs 277
Exporting Data 277
CSV Export 277
Compressed 278
Importing Data 279
Deleting Haul Cycle Records 279
Viewing Alarms 280
Deleting Alarm Records 280
TROUBLESHOOTING SECTION 281
TROUBLESHOOTING 281
Viewing Active Alarms 281
Real-Time Data Display 281
Testing the Payload Lights 281
Creating Log Files of Inputs 282
Daily Inspections 282
Periodic Maintenance 282
Abnormal Displays at Power-Up 283
No Payload Display When Key Switch is Turned ON 284
No Display on Speedometer 285
No Display on Operator Display 285
No Communications With PC 286
Load Lights Don’t Light During Loading 287
Load Lights Remain ON 288
Load Lights Remain ON During Dumping 288
Display Doesn’t Clear When The Load Is Dumped 288
Calibration Problems 289
Alarm 1 – Left Front Pressure High 290
Alarm 2 – Left Front Pressure Low 290
Troubleshoot Wiring to Left Front Suspension 290
Alarm 3 – Right Front Pressure High 291
Alarm 4 – Right Front Pressure Low 291
Troubleshoot Wiring to Right Front Suspension 291
Alarm 5 -Left Rear Pressure High 292
Alarm 6 – Left Rear Pressure Low 292
Troubleshoot Wiring to Left Rear Suspension 292
Alarm 7 – Right Rear Pressure High 293
Alarm 8 – Right Rear Pressure Low 293
Troubleshoot Wiring to Right Rear Suspension 293
Alarm 9 – Inclinometer High 294
Alarm 10 – Inclinometer Low 294
Troubleshoot Inclinometer Wiring 294
Alarm 13 – Body Up Input Failure 295
Alarm 16 – Memory Write Failure 296
Alarm 17 – Memory Read Failure 296
Alarm 18 296
Alarm 19 296
Alarm 22 296
Operator Switch Doesn’t Work 297
Alarm 26 – User Switch Fault – SELECT 297
Alarm 27 – User Switch Fault – SET 297
Connector Map 298
Connectors 299
General Description 300
Tools Required 300
Checkout Procedure 300
PLMIII CHECKOUT PROCEDURE CONFIRMATION 304
Flashburn Programming 304
Confirmation Checklist 306
SECTION E ELECTRICAL PROPULSION INDEX 307
SECTION E2 ELECTRICAL PROPULSION COMPONENTS INDEX 309
GENERAL SYSTEM DESCRIPTION 313
CONTROL SYSTEM 313
System Operation 314
FL275 Panel 315
CARD REPLACEMENT 316
Removal 316
Installation 316
Card Repair 316
Panel Wiring 316
COMPUTER DESCRIPTION 317
Microprocessor 317
Download Capability 317
SOFTWARE 317
Base Monitor Program 317
Runtime Monitor Program – OBJ Running Code 317
Configuration Software – CFG 318
PTU – Portable Test Unit Code 318
System Regulation 318
Propulsion 319
Retarding 319
TWO-DIGIT DISPLAY PANEL 320
The Coded Number 320
Events 320
Frames 321
Windows 321
System Categories 321
Limits On Resetting Faults 321
NA Faults 322
Event Sequence 322
Resetting Events 322
Event Descriptions 322
Subcode Descriptions 322
PORTABLE TEST UNIT (PTU) 333
DESCRIPTION 333
Operational Hints 333
SOFTWARE INSTALLATION PREPARATION 334
HARD DISK SPACE REQUIREMENTS 334
SOFTWARE INSTALLATION ON PTU 334
PTU/Truck Communication Problems 335
THE MAIN MENU 336
Quit Menu 336
PTU Talk To Truck 336
View PTU Saved Files 336
List Stat Data Files 336
Truck Setup (CFG) 336
Select Truck Setup 336
Update CFG Version 336
Change PTU Password 336
CONFIGURATION (CFG) FILE CONVERSION 338
Conversion Procedure 338
Convert Old CFG files for New software 339
STATEX CONFIGURATION FILES 342
0) Source Directory: 342
1) Select A Truck Configuration 343
2) View Truck Configuration: Data Curves 344
3) Change/View Serial and Model Numbers 345
4) View Options 345
5) Change/View Truck Specifics 347
6) Change/View Overspeeds 349
7) Save a Truck Configuration, filename: 350
8) Save Directory: 351
CHANGE PTU PASSWORD 352
PROGRAMMING THE TRUCK 353
Connect PTU to the Truck 353
Select Configuration File 353
Activate The PTU Mode 353
Check Object Code Version 354
Download Configuration Files 355
Date And Time 356
Event Data 357
Statistical Data 359
View Counters 359
View Profiles 359
Upload Statistical Data To A File 359
Statistical Data Codes – Counters 360
STATISTICAL DATA CODES – COUNTERS 361
STATISTICAL DATA CODES – PROFILES 366
TRUCK SPECIFIC INFORMATION 370
Temporary Truck Settings 371
MISCELLANEOUS FEATURES 372
Saving Data 372
PTU Abbreviations 373
Other Menu Selections 373
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 374
ALTERNATOR 374
ELECTRIC WHEEL MOTORS 374
RETARDING GRIDS 374
ELECTRONIC ACCELERATOR AND RETARD PEDALS 374
Removal 374
Installation 374
Disassembly 375
Reassembly 375
COOLING BLOWER WARNING SYSTEM 375
Operation 375
Test 375
Removal 376
Installation 376
ELECTRICAL CONTROL CABINET 377
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 382
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 383
2-DIGIT DISPLAY PANEL SUBCODES 330
SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX 385
GENERAL INFORMATION 389
COMMUNICATIONS PORT CHECK 390
PTU Hookup 390
4 0 SEQUENCE TESTS – (ENGINE NOT ON) 391
Preparation and Setup 391
CONTROL SYSTEM SELF-TEST 392
4 1 THROTTLE SYSTEM CHECK AND ADJUSTMENT 392
4 2 RETARD SYSTEM CHECK AND ADJUSTMENT 393
PTU Setup 393
4 3 REVERSER AND PROPULSION CONTACTORS CHECK 394
4 4 NOT USED 395
4 5 RETARD CONTACTORS OPERATION CHECK 395
4 6 GROUND FAULT SENSING CHECK 395
4 7 GROUND FAULT IN RETARD OPERATION CHECK 396
4 8 OVERRIDE OPERATION CHECK 396
4 9 ANTI-REVERSAL FUNCTION (AR) CHECK 397
4 10 OVERSPEED RETARD OPERATION CHECK 397
4 11 HOIST INTERLOCK OPERATION CHECK 398
4 12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK 398
Return to Main Menu 398
5 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 399
5 1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU 399
5 2 DIGITAL INPUT CHECKS 400
5 3 DIGITAL OUTPUT CHECKS 401
6 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 405
6 1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU 405
6 2 ANALOG INPUT CHECKS 406
6 3 FREQUENCY INPUT CHECKS 410
Return to Main Menu 411
7 0 SPEED EVENT CHECKS 411
Preparation and Setup 411
Setup PTU 411
7 1 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK 412
7 2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK 412
7 3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK 412
7 4 OTHER SPEED EVENTS CHECKS 412
Return to Main Menu 412
8 0 RETARD SPEED CONTROL SYSTEM CHECK 413
Preparation and Setup 413
Setup PTU 413
8 1 OVERSPEED PICKUP AND DROPOUT CHECK 413
8 2 RETARD POT MAXIMUM SETTING CHECK 413
8 3 RETARD POT MINIMUM SETTING CHECK 413
8 4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL 414
Return to Main Menu 414
9 0 LOAD TEST USING TRUCK RETARD GRIDS 414
Setup and Preparation 414
PTU Setup 414
9 1 LOAD TEST 415
10 0 MOTOR FIELD CURRENT CHECK IN RETARDING 415
Setup PTU 415
10 1 RETARD CHECK 416
11 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 417
11 1 BRAKE SYSTEM INTERLOCKS CHECK 417
Preparation 417
11 2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT 417
11 3 SYNC TRANSFORMER CHECKOUT 418
11 4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT 418
11 5 BATTERY BOOST ADJUSTMENT 418
11 6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST 418
11 7 MOTOR ROTATION TEST 419
11 8 GROUND FAULT CHECKS 419
12 0 MISCELLANEOUS CHARTS 420
12 1 WHEEL MOTOR GEAR RATIOS 420
12 2 MAXIMUM ALLOWABLE TRUCK SPEEDS 421
12 3 ENGINE 422
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX 423
SECTION G2 TIRES AND RIMS INDEX 425
GENERAL INFORMATION 427
TIRES 427
Handling Tires 427
Tire Maintenance 428
Storing Tires After Removal 428
FRONT TIRES AND RIMS 429
Removal 429
Installation 430
REAR TIRES AND RIMS 431
Removal 431
Installation 432
RIM 433
Tire Removal 433
RIM AND TIRE PREPARATION 434
LUBRICANTS 434
TIRE INSTALLATION 435
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 437
FRONT WHEEL HUB AND SPINDLE 439
WHEEL HUB AND SPINDLE ASSEMBLY 439
Removal 439
Installation 441
Disassembly 442
Cleaning and Inspection 443
Assembly 443
Wheel Bearing Adjustment (Spindle Vertical) 446
Wheel Bearing Adjustment (Tire Mounted) 447
Spindle Removal Procedure (Optional) (off of the truck) 450
STEERING CYLINDERS AND TIE ROD 452
Spherical Bearing Wear Limits 452
Removal 453
Installation 455
Bearing Replacement 455
TOE-IN ADJUSTMENT 456
SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX 457
PIVOT PIN 459
Removal 459
Installation 460
PIVOT EYE BEARING 460
Disassembly 460
Assembly 461
PIVOT EYE REPAIR 461
Removal 461
Disassembly 461
Bushing (New) 461
Pivot Eye Bore (New) 461
Assembly 461
Installation 462
ANTI-SWAY BAR 462
Removal 462
Installation 462
Disassembly 463
Cleaning and Inspection 463
Assembly 463
SECTION G5 REAR AXLE HOUSING INDEX 465
REAR AXLE HOUSING 467
Removal 467
Installation 467
WHEEL MOTOR 467
Removal 467
Cleaning and Inspection 468
Installation 468
Maximum Cap Screw Usage 468
SECTION H SUSPENSIONS INDEX 471
SECTION H2 FRONT SUSPENSION INDEX 473
Removal 475
Installation 477
Angle Advance Tightening Procedure 478
Disassembly 479
Cleaning and Inspection 480
Assembly (Bearing Only) 480
Suspension Assembly (Complete) 480
SUSPENSION PRESSURE TEST 482
SECTION H3 REAR SUSPENSIONS INDEX 485
Removal 488
Installation 490
Disassembly 490
Cleaning and Inspection 491
Assembly 491
SUSPENSION PRESSURE TEST 493
SECTION H4 OILING AND CHARGING PROCEDURES INDEX 495
GENERAL 497
EQUIPMENT LIST 497
Hydrair® Charging Kit 497
Installation of Charging Kit 497
Removal of Charging Kit 498
Support Blocks For Oiling and Charging Dimensions 498
FRONT SUSPENSION 499
Front Suspension Oiling 499
Front Suspension Nitrogen Charging 500
REAR SUSPENSION 502
Rear Suspension Oiling 502
Rear Suspension Nitrogen Charging 504
SECTION J BRAKE CIRCUIT INDEX 507
SECTION J2 BRAKE CIRCUIT INDEX 509
GENERAL DESCRIPTION 511
SERVICE BRAKE CIRCUIT 511
SECONDARY BRAKING AND AUTOMATIC APPLY 513
PARKING BRAKE CIRCUIT 513
Normal Operation (key switch on, engine on) 513
BRAKE LOCK CIRCUIT 514
WARNING CIRCUIT 514
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 517
BRAKE VALVE 519
Rebuild Criteria 519
Removal 520
Installation 520
DISASSEMBLY 522
Cleaning and Inspection 523
ASSEMBLY 525
Actuator Base Threaded Inserts 525
Boot and Cap 525
Valve Body Seal Installation 526
Regulator Sleeve O-Ring Installation 526
Actuator Plunger O-ring Installation 526
Assembly of Valve 526
DIFFERENTIAL PRESSURE SWITCH 528
Disassembly 528
Cleaning and Inspection 528
Assembly 528
VALVE BENCH TEST AND ADJUSTMENT 529
Test Set Up Procedure 529
Brake Valve Output Pressure Adjustment 531
Differential Pressure Switch Test 532
Final Test and Adjustment 532
Installation Of Brake Pedal Actuator Assembly to Brake Valve 533
HYDRAULIC BRAKE ACCUMULATORS 535
Brake Accumulator Bleed Down Procedure 535
Removal 535
Installation 535
Disassembly 536
Cleaning and Inspection 537
Assembly 537
Leak Testing 539
BRAKE ACCUMULATOR CHARGING 540
Temperature During Precharge 542
ACCUMULATOR STORAGE 542
Installation 543
Bladder Storage 543
BRAKE MANIFOLD 544
Removal 544
Removal 544
Installation 545
Disassembly 545
Cleaning and Inspection 545
Assembly 545
BRAKE CIRCUIT CHECK-OUT PROCEDURE 549
EQUIPMENT REQUIRED 551
INITIAL SYSTEM SET-UP 552
Parking Brake 552
Service Brakes 553
Brake Lock/Secondary 553
Low Brake Pressure and Auto Apply 554
Reapplications 554
Differential Pressure Switch 554
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 556
The Brakes are Locked, Service, and/or Parking 556
Both Brake Circuits are Dragging 556
One Brake Circuit is Dragging 556
Brakes are Not Going to Full Pressure 556
A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off 556
Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released 557
Differential Pressure Warning Circuit is Not Operating 557
A Low Brake Pressure Warning Occurs When Brakes are Applied 557
Low Pressure Warning Circuit Not Operating Properly 557
Low Pressure Warning is On Even Though System Pressure is Correct 558
Low Pressure Warning Comes On and Pressure is Low 558
A Squeal is Heard When Controller is Operated 558
Output Pressure At Controller is Correct but Brakes are Not Applying 558
Brake Pressures Drift Excessively While Pedal is Held Steady 558
Oil is Leaking Around the Pedal Base 558
Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM 558
Low Pressure Warning is On Even Though System Pressure is Correct 559
Low Pressure Warning Comes On and Pressure is Low 559
A Squeal is Heard When Controller is Operated 559
Output Pressure At Controller is Correct but Brakes are Not Applying 559
Brake Pressures Drift Excessively While Pedal is Held Steady 559
Oil is Leaking Around the Pedal Base 559
Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM 559
HYDRAULIC BRAKE SYSTEM DATA SHEET 560
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 547
SECTION J5 FRONT DISC BRAKES INDEX 563
BRAKE CALIPER 565
Removal 565
Installation 566
Disassembly 567
Cleaning and Inspection 567
Assembly 569
BRAKE LINING 569
Replacement 569
FRONT SERVICE BRAKE BURNISHING 571
BRAKE BLEEDING PROCEDURE 572
REAR DISC BRAKES 575
REAR BRAKES 575
CALIPER, DISC, AND PARKING BRAKE 575
Removal 575
Installation 576
CALIPER PISTON 578
Piston Assembly Removal 578
Inspection 578
Piston Assembly Installation 579
FUNCTIONAL TEST OF PISTON ASSEMBLY 580
Return Spring Force 580
Built-In Clearance 580
Grip Force 582
Grip Force Measurement 583
Spring Force Measurement 585
Disassembly of Piston Assembly 586
Assembly of Piston Assembly 587
BENCH TEST 587
BRAKE LINING 588
Replacement 588
SERVICE BRAKE BURNISHING 591
SAFETY PRECAUTIONS 591
Rear Brake Burnishing 592
BRAKE BLEEDING PROCEDURE 593
Spring Force Measurement 594
SECTION J6 REAR BRAKES INDEX 573
SECTION J7 PARKING BRAKE INDEX 595
GENERAL INFORMATION 597
PARKING BRAKE CALIPER 597
Lining Thickness Inspection 597
Removal 598
Installation 598
Parking Brake Adjustment 599
Parking Brake Caliper Disassembly 600
Cleaning and Inspection 601
Parking Brake Caliper Assembly 602
PARKING BRAKE LINING REPLACEMENT 602
PARKING BRAKE BURNISH PROCEDURE 602
Lining Conditioning 602
BRAKE BLEEDING PROCEDURE 603
SECTION L HYDRAULIC SYSTEM INDEX 605
SECTION L2 HYDRAULIC SYSTEM OVERVIEW 607
HYDRAULIC SYSTEM OVERVIEW 608
Hoist Circuit Operation 608
Steering, Brake and Pantograph Circuit Operation 608
Axle Blower System Operation 608
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 611
HYDRAULIC SYSTEM COMPONENT REPAIR 613
HOIST PUMP 613
Removal 613
Installation 615
Disassembly 615
Inspection 618
Assembly 619
PISTON PUMP 624
Removal 624
Installation 625
Disassembly 627
Inspection of Parts 633
Assembly 635
AXLE BLOWER HYDRAULIC MOTOR 640
Removal 640
Installation 640
Rear Axle Blower Housing 640
Disassembly 640
Assembly 641
Disassembly 643
Inspection 645
Assembly 646
Trouble Shooting 647
Hand Wheel Control 648
Disassembly 648
Assembly 648
HYDRAULIC TANK 650
Filling Instructions 650
Removal 651
Installation 651
HYDRAULIC TANK STRAINER AND DIFFUSER 652
Removal 652
Inspect and Clean 653
Installation 653
SECTION L4 STEERING CIRCUIT INDEX 655
STEERING CIRCUIT OPERATION 657
COMPONENT DESCRIPTION 658
Steering Control Valve 658
Unloader Valve 659
Bleed-Down Manifold Valve 659
Flow Amplifier 664
FLOW AMPLIFIER SYSTEM OPERATION 665
No Steer 665
Steering Left 667
Steering Right 669
No Steer, External Shock Load 671
Steering Pump 673
High Pressure Filter 673
Accumulators 673
Low Precharge Warning Switch 673
SECTION L5 STEERING CONTROL VALVE INDEX 675
Removal 677
Installation 678
STEERING CONTROL VALVE REBUILD 679
Disassembly 679
Cleaning and Inspection 680
Assembly 680
BRAKE / STEERING PUMP 684
Removal 684
Installation 686
Disassembly 687
Inspection of Parts 687
Assembly 689
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 691
BLEED-DOWN MANIFOLD 693
Removal 693
Installation 693
ACCUMULATOR 694
Removal 694
Installation 695
Disassembly 696
Cleaning and Inspection 696
Assembly 697
Leak Testing 698
STEERING ACCUMULATOR CHARGING 699
Temperature During Precharge 702
ACCUMULATOR STORAGE 703
Installation 703
FLOW AMPLIFIER 704
Removal 704
Installation 704
Disassembly 705
Assembly 708
STEERING CYLINDERS 709
Disassembly 709
Piston Seal and Bearing Installation 709
Cylinder Assembly 709
Test 709
SECTION L7 HOIST CIRCUIT INDEX 717
HOIST CIRCUIT OPERATION 719
COMPONENT DESCRIPTION 720
Hydraulic Tank 720
Hydraulic Pump 720
High Pressure Filter 720
Hoist Valve 720
Hoist Pilot Valve 721
Bleed-Down Manifold 722
Counterbalance Manifold 722
Hoist-Up Limit Solenoid 722
Pilot Operated Check Valve 722
HOIST VALVE OPERATION 724
Float Operation 724
Power Up Operation (Figure 7-6) 726
Hold Operation (Figure 7-7) 728
Power Down Operation (Figure 7-8) 730
Float Operation (Figure 7-9) 732
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 735
HOIST VALVE 737
Removal 737
Installation 737
O-Ring Replacement 739
INLET SECTION 740
Disassembly 740
Cleaning and Inspection 741
Assembly 741
REAR SPOOL SECTION (WORK PORTS) 742
Disassembly 742
Cleaning and Inspection 744
Assembly 744
HOIST PILOT VALVE 746
Removal 746
Installation 746
Disassembly 747
Cleaning and Inspection 748
Assembly 748
HOIST UP LIMIT SOLENOID VALVE 749
HOIST CYLINDERS 750
Removal 750
Installation 751
Disassembly 753
Cleaning and Inspection 754
SS1143 Tightening Tool – Assembly Drawing 755
ASSEMBLY OF QUILL AND CYLINDER 755
Quill Installation 755
Installation Of Check Balls And Plugs In Quill 756
Assembly of Cylinder 758
Pressure Testing 759
COUNTERBALANCE MANIFOLD 759
SECTION L9 HIGH PRESSURE FILTERS INDEX 761
HOIST CIRCUIT FILTER 763
Filter Element Replacement 763
Removal 764
Installation 764
Indicator Switch 764
STEERING CIRCUIT FILTER 765
Filter Element Replacement 765
Removal 766
Installation 766
Indicator Switch 766
INDICATOR SWITCH 766
Test Procedure 766
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE 769
Initial Start Up and Flushing (Steps 5 – 22) 770
Component Checkout and Adjustment (Steps 23 – 34) 771
Adjustment Procedure for Hoist Counterbalance Cartridge Valve (Steps 34a-34l) 773
Counterbalance Valve Adjustment (Steps f & g): 774
Manifold reassembly (steps i through k): 774
Piston Pump and Axle Box Hydraulic Motor Adjustment (Steps 35 – 50) 775
Oil Cleanliness Check 776
Oil Sampling Location on Truck: 776
Oil Sampling Process and Cleanliness Criteria: 776
DISABLED TRUCK DUMPING PROCEDURE 777
HOOKUP 777
DUMPING PROCEDURE 777
Raising the Body: 777
Lowering the Body: 777
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 785
SECTION M4 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM INDEX 787
SYSTEM ADJUSTMENT 789
PUMP 792
Removal 792
Disassembly 792
Inspection 792
Assembly 792
Installation 792
BLOWER DRIVE MOTOR 795
Removal 795
Disassembly 795
Inspection Of Parts 796
Assembly 797
Installation 798
BLOWER BEARING REPAIR 798
Removal 798
Replacement 798
Assembly 799
AIR CLEANER 799
Assembly 799
Removal 799
Assembly 799
SECTION M7 HEATER OPTIONS INDEX 801
GENERAL INFORMATION 803
TROUBLESHOOTING 803
HEATER ELEMENT 803
Removal 803
Installation 804
GENERAL 805
Maintenance 805
HEATING ELEMENT 805
Removal 805
Installation 806
THERMOSTAT 806
Removal 806
Installation 806
GENERAL INFORMATION 807
TROUBLESHOOTING 807
HEATER ELEMENT 807
Removal 807
Installation 808
SECTION M8 SPECIAL TOOLS 809
NITROGEN CHARGING VALVE 809
ROLL-OUT ASSEMBLY 809
EYE BOLT 809
OFFSET WRENCH 810
TORQUE ADAPTER 810
HANDLE 810
SEAL INSTALLER 810
SLEEVE ALIGNMENT TOOLS 811
QUICK DISCONNECT COUPLING 811
HARNESS 811
SEAL INSTALLATION RING 811
BELT TENSION TESTER 812
BELT ALIGNMENT TOOL 812
SOCKETS AND ADAPTERS 812
DUST CAPS 812
HYDRAULIC SYSTEM FLUSHING TOOLS 813
PAYLOAD DATA MANAGER 813
HYDRAULIC SYSTEM VACUUM PUMP 813
MISCELLANEOUS SERVICE TOOLS 814
BRAKE PISTON TOOL 815
HIGH VOLTAGE TOOLS 818
2000 VDC METER 818
GROUNDING STICKS 818
BODY PAD SPACER TOOL 819
RADIATOR SHUTTERS 823
OPERATION 823
Hydraulic Circuit 823
Electrical Circuit: 824
MAINTENANCE AND REPAIR 824
TROUBLESHOOTING 825
Hydraulic Troubleshooting 828
Electrical Troubleshooting 830
SECTION M19 RADIATOR SHUTTERS INDEX 821
SECTION N OPERATOR’S CAB INDEX 831
SECTION N2 TRUCK CAB INDEX 833
TRUCK CAB 836
TRUCK CAB 836
Description 836
Removal 837
Installation 839
CAB DOOR 839
Removal 839
Installation 840
Door Adjustment 840
Door Jam Bolt Adjustment 840
Door Handle Plunger Adjustment 842
Replace Door Glass 843
Replace Door Window Regulator 847
Replace Door Handle or Latch Assembly 847
Door and Door Hinge Seal Replacement 848
Door Opening Seal Removal 848
Installation 848
GLASS REPLACEMENT 849
Adhesive-Bonded Windows 849
Recommended Tools/Supplies 849
Replacement Procedure 849
Windshield and Rear Glass 850
Removal 850
Installation 851
Removal and Installation of Operator Seat 852
Inspection 852
Removal 852
Installation 852
Removal and Installation of Passenger Seat 853
Removal 853
Installation 853
SECTION N3 CAB COMPONENTS INDEX 855
WINDSHIELD WIPERS 857
WIPER MOTOR REPLACEMENT 857
Removal 857
Installation 857
WIPER ARM REPLACEMENT 857
Removal 857
Installation 858
WIPER LINKAGE REPLACEMENT 858
Removal 858
Installation 859
WINDSHIELD WASHER 859
Operation 859
Service 859
SEAT BELT 860
Removal 860
Installation 860
SECTION N4 OPERATOR COMFORT INDEX 863
HEATER/AIR CONDITIONER 867
CONTROLS 867
Operation 867
Heater/Air Conditioner Vents 867
Defroster Vent Control Switch 867
Heat Control Switch 867
Temperature Control Knob 867
Fan Control Knob 867
Heater/Air Conditioner Selector Switch 867
COMPONENTS 868
Circuit Breakers 868
Relays 868
Heater Core 868
Fan Motor and Speed Control 869
Test 869
Actuators 869
Test 869
Cab Air Filter 870
AIR CONDITIONING SYSTEM 872
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 873
PRINCIPLES OF REFRIGERATION 873
Air Conditioning 873
Refrigeration – The Act of Cooling 874
The Refrigeration Cycle 874
AIR CONDITIONER SYSTEM COMPONENTS 875
Compressor (Refrigerant Pump) 875
Service Valves 875
Receiver-Drier 875
Condenser 875
Expansion Block Valve 876
Accumulator 876
Evaporator 877
ELECTRICAL CIRCUIT 877
Thermostat 877
Compressor Clutch 878
Trinary™ Switch 878
SYSTEM SERVICING 880
SERVICE TOOLS AND EQUIPMENT 881
Recovery/Recycle Station 881
Leak Detector 882
Service Valves 882
Vacuum Pump 882
Manifold Gauge Set 883
Low Side Gauge 883
High Side Gauge 883
Installing Manifold Gauge Set 884
Purging Air From Service Hoses 884
SYSTEM PERFORMANCE TEST 885
SYSTEM OIL 886
Handling and Reusing RPAG Oil 886
Oil Quantity 886
Checking System Oil 886
REFRIGERANT 887
Recycled Refrigerant 887
Reclaimed Refrigerant 887
Refrigerant Quantity 888
R-134a Refrigerant Containers 888
SYSTEM LEAK TESTING 888
Electronic Leak Detector 889
Tracer Dyes 889
Soap and Water 889
RECOVERING AND RECYCLING THE REFRIGERANT 889
Performing the Recovery Cycle 889
Performing the Recycling Procedure 890
Evacuating and Charging the A/C System 890
SYSTEM REPAIR 890
System Flushing 891
COMPONENT REPLACEMENT 891
Hoses and Fittings 891
Lines 891
Expansion Valve 892
Receiver-Drier 892
Thermostat 892
Compressor 892
Accumulator 893
Clutch 893
Servicing the Compressor Clutch 894
Pulley Removal 896
Clutch Coil Check 896
Pulley Installation 897
Clutch Assembly Installation 897
EVACUATING THE SYSTEM 898
CHARGING THE A/C SYSTEM 900
AIR CONDITIONER DRIVE BELT 900
Pulley Alignment 900
Belt Tension 901
TROUBLESHOOTING 902
Preliminary Checks 902
Diagnosis of Gauge Readings and System Performance 903
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 904
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 910
SECTION N5 OPERATOR CONTROLS 911
OPERATOR CONTROLS 913
STEERING WHEEL AND CONTROLS 914
STEERING WHEEL 914
HORN BUTTON 914
TILT/TELESCOPE LEVER 914
MULTI-FUNCTION TURN SIGNAL SWITCH 914
Turn Signal Operation 915
High Beam Headlight Operation 915
Windshield Wiper Operation 915
STEERING COLUMN 915
Removal 915
Inspection 916
Installation 916
PEDALS 916
SERVICE BRAKE PEDAL 916
DYNAMIC RETARDER PEDAL 917
Optional – Dual Function/Single Pedal 917
THROTTLE PEDAL 917
OVERHEAD PANEL CONTROLS AND COMPONENTS 918
GRADE/SPEED WARNING CHART 918
RADIO SPEAKERS 918
WINDSHIELD WIPERS 918
WARNING ALARM BUZZER 918
CAB RADIO 918
WARNING LIGHTS DIMMER CONTROL 918
WARNING/STATUS INDICATOR LIGHT PANEL 918
AIR CLEANER VACUUM GAUGES 918
CENTER CONSOLE 919
TRUCK CONTROLS 920
F-N-R Selector Switch 920
Hoist Control Lever 920
Trolley Master Control Lever 920
CONSOLE SWITCHES AND CONTROLS 920
Cigarette Lighter 920
Window Control Switches 920
Engine Shutdown Switch 920
Override Switch 921
Retard Speed Control (RSC) Switch 921
Retard Speed Control (RSC) Dial 921
Statex III Download Port 922
Engine Diagnostic Port (CENSE) 922
Engine Diagnostic Connectors 922
Data Storage Button 922
Passenger Seat 922
PAYLOAD METER 923
Payload Meter Download Connector 923
CAB CLIMATE CONTROL 924
HEATER/AIR CONDITIONER VENTS 924
HEATER/AIR CONDITIONER CONTROLS AND VENTS 924
Defroster Vent Control Switch 924
Heat Control Switch 924
Temperature Control Knob 924
Fan Control Knob 924
Heater/Air Conditioner Vents 924
OPERATOR SEAT 925
ADJUSTMENT 925
INSTRUMENT PANEL 926
GENERAL INFORMATION 926
CONTROL SYMBOLS 926
CONTROL SWITCHES AND GAUGES 927
Key Switch 928
Engine Shutdown Switch With Timer Delay 928
Fog Light Switch 928
Ladder Light Switch 928
Backup Light Switch 928
Panel Illumination Lights 928
Cab Air Conditioner/Heater Vents 928
Engine Cold Weather Starting Aid Switch 928
Rotating Beacon Light Switch 929
Heated Mirror Switch 929
Wheel Brake Lock Switch 929
Leakage Test Switch (Trolley Option Only) 929
Parking Brake Switch 929
Digital Tachometer 929
Right Turn Signal Indicator Light 930
High Beam Headlight Indicator Light 930
Left Turn Signal Indicator Light 930
Digital Speedometer/Payload Meter Display 930
Voltmeter Gauge 930
Engine Oil Pressure Gauge 930
Engine Water Temperature Gauge 930
Fuel Gauge 930
Engine Hourmeter 931
Headlight Switch 931
Panel Illumination Lights Dimmer Rheostat 931
Payload Meter Switch 931
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL 932
INDICATOR LIGHT FUNCTIONS 933
High Hydraulic Oil Temperature 933
Low Steering Pressure 933
Low Accumulator Precharge Pressure Warning 933
Electric System Fault Warning 934
Low Brake Pressure Indicator 934
Low Hydraulic Tank Level 934
Low Automatic Lubrication System Pressure 934
Circuit Breaker Tripped 934
Hydraulic Oil Filter 934
Low Fuel Indicator 935
Parking Brake Indicator 935
Service Brake Indicator 935
Body Up Indicator 935
Dynamic Retarding Indicator 935
Stop Engine Warning 935
Backup Indicator 935
Engine Shutdown Timer Switch- Five Minute Idle 935
Retard Speed Control 935
Service Engine Indicator (AEM) 936
High Wheel Motor Temperature Indicator 936
Blower Fault Warning 936
Service Engine Indicator (CENSE) 936
Komatsu Engines w/Centry™ Fuel Control 936
Hazard Warning Light Switch 936
Lamp Test Switch/Centry™ Diagnostic Test Switch 936
Backup Lights 940
Retard Lights 940
Brake Light 940
Backup Alarm 940
CENTRY™ FUEL SYSTEM DIAGNOSTICS 941
GENERAL OPERATION 941
DETERMINING FAULT CODES 941
EXITING THE DIAGNOSTICS MODE 942
SECTION P LUBRICATION AND SERVICE INDEX 943
SECTION P2 LUBRICATION AND SERVICE INDEX 945
GENERAL INFORMATION 947
HYDRAULIC TANK SERVICE 947
Adding Oil 947
COOLANT LEVEL CHECK 948
Radiator Filling Procedure 948
Coolant Specifications 948
Unacceptable Practices 948
WHEEL MOTOR SERVICE 948
RESERVE ENGINE OIL SYSTEM (Optional) 949
Reserve Oil Tank Filling Procedure (Remote fill) 949
Inline Screen 949
QUICK FILL SERVICE CENTER 950
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS 952
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued) 953
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 954
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 954
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 955
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 956
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 957
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 958
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 959
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS 960
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS 960
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 961
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS 962
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 963
GENERAL DESCRIPTION 965
SYSTEM COMPONENTS 966
Filter Assembly 966
Hydraulic Motor and Grease Pump 966
Reservoir 966
Fixed Pressure Reducing Valve 966
Flow Control Valve 966
Solenoid Valve 967
Vent Valve 967
24VDC Lubrication Cycle Timer 967
Time Delay Module 967
Pump Cutoff Pressure Switch 967
Unloader Valve 967
Pressure Switch 967
Manual Override Button 967
Injectors 967
SYSTEM OPERATION 970
Normal Operation 970
Pressure Failure Detection Circuits 971
GENERAL INSTRUCTIONS 972
LUBRICANT REQUIRED FOR SYSTEM 972
SYSTEM PRIMING 972
LUBRICANT PUMP 973
Pump Housing Oil Level 973
Pump Pressure Control 973
FILTER AND RESERVOIR 973
Filter Assembly Element 974
INJECTORS (SL-1 Series H) 974
Injector Specifications 974
Injector Adjustment 974
INJECTOR OPERATION 976
SYSTEM CHECKOUT 977
Lubrication Cycle Timer Check 977
Lubrication Cycle Timer Adjustment 978
PREVENTIVE MAINTENANCE INSPECTION 978
10 Hour Lubrication System Inspection 978
100 Hour Inspection 978
250 Hour Inspection 978
500 Hour Inspection 979
1000 Hour Inspection 979
PUMP REBUILD 980
Disassembly 980
Cleaning and Inspection 980
Assembly 982
VENT VALVE REBUILD 983
Disassembly and Assembly 983
SYSTEM TROUBLESHOOTING CHART 984
MOTORIZED WHEEL MAINTENANCE SCHEDULE 989
AXLE BOX 989
MOTORIZED WHEEL MAINTENANCE SCHEDULE 990
ARMATURE AREA 990
AT TIRE CHANGE 990
MOTORIZED WHEEL MAINTENANCE SCHEDULE 991
GENERATOR/ALTERNATOR 991
GRID BLOWER MOTOR 991
CONTROL EQUIPMENT CHECKS 991
MOTORIZED WHEEL MAINTENANCE SCHEDULE 992
VEHICLE OPERATIONS TESTS 992
SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX 987
SECTION R SYSTEM SCHEMATICS INDEX 993
EJ1735 HYDRAULIC BRAKE SYSTEM SCHEMATIC 995
EK3630 HYDRAULIC SYSTEM SCHEMATIC 996
XS1000 ELECTRICAL SCHEMATIC 997

S.V 12/12/24