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Komatsu 730E Trolley Dump Truck Shop Manual SN A30355, A30392, A30393, A30403 & A30406 PDF DOWNLOAD
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Komatsu 730E Trolley Dump Truck Shop Manual
Book Code: CEBM016301
SERIAL NUMBERS:
A30355, A30392, A30393, A30403 & A30406
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Description
Komatsu 730E Trolley Dump Truck Shop Manual
FILE DETAILS:
Komatsu 730E Trolley Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 730E
Serial Number: A30355, A30392, A30393, A30403 & A30406
Language: English
Book Code: CEBM016301
Pages: 1090
File Format: Portable Document Format (PDF)
KOMATSU 730E TROLLEY DUMP TRUCK SHOP MANUAL SN A30355, A30392, A30393, A30403 & A30406 PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 730E Trolley Dump Truck Shop Manual
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 lb). 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.
TABLE OF CONTENTS:
Komatsu 730E Trolley Dump Truck Shop Manual
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
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