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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30625 – A30649) KOMATSU 830E – PDF DOWNLOAD
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- KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30625 – A30649
- PUBLICATION NUMBER:CEBM006301
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Description
KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30625 – A30649) KOMATSU 830E
KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30625 – A30649) KOMATSU 830E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30625 – A30649) KOMATSU 830E
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit.
- The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and 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 general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30625 – A30649) KOMATSU 830E
COVER.............................................................................................................................................. 1 FOREWARD........................................................................................................................................... 7 CONTENTS........................................................................................................................................... 9 GENERAL INFORMATION................................................................................................................................ 11 TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS................................................................................................... 13 GENERAL SAFETY AND TRUCK OPERATION............................................................................................................. 17 WARNINGS AND CAUTIONS.......................................................................................................................... 45 CHARTS AND TABLES.............................................................................................................................. 51 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values....................................................................... 51 Standard Assembly Torques For 12-Point, Grade 9, Cap Screws (SAE).......................................................................... 52 Standard Metric Assembly Torque For Class 10.9 Cap Screws & Class 10 Nuts.................................................................. 52 Suggested* Sources for Rust Preventive Grease:............................................................................................. 52 STORAGE AND IDLE MACHINE PREPARATION........................................................................................................... 57 SHORT TERM IDLE PERIODS.................................................................................................................... 57 REMOVAL FROM STORAGE....................................................................................................................... 59 RECONDITIONING AN IDLE VEHICLE............................................................................................................. 61 ENGINE OPERATION........................................................................................................................... 64 AFTER ENGINE HAS STARTED................................................................................................................... 65 ENGINE STORAGE-CUMMINS..................................................................................................................... 66 Engine Storage-(Short Term)............................................................................................................ 66 Prepare the Engine for Short Term Storage.............................................................................................. 66 Remove the Engine from Short Term Storage.............................................................................................. 66 Engine Storage- (Long Term)............................................................................................................ 67 6 Months to 24 Months.............................................................................................................. 67 Prepare the Engine for Long Term Storage............................................................................................... 67 Remove the Engine from Long Term Storage............................................................................................... 67 PREPARATION FOR STORAGE.................................................................................................................... 58 ENGINE STORAGE - DETROIT DIESEL............................................................................................................ 68 Preparing Engine For Storage........................................................................................................... 68 Temporary Storage (30 Days Or Less).................................................................................................... 68 Extended Storage (more Than 30 Days)................................................................................................... 68 PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE............................................................ 70 ELECTRIC DRIVE TRUCKS...................................................................................................................... 71 Storage Instructions and Procedures.................................................................................................... 71 Placing Equipment Into Storage......................................................................................................... 71 When Storing A Truck That Is Operational............................................................................................... 71 When Storing A Truck That Is Not Operational........................................................................................... 72 When Storing A Major Component......................................................................................................... 72 Periodic Inspections................................................................................................................... 73 Placing Equipment Into Service After Storage........................................................................................... 73 When A Truck Is Operational........................................................................................................ 73 When A Truck Is Not Operational.................................................................................................... 73 For The First Hour................................................................................................................. 74 PRESERVATION AND STORAGE ALLISON TRANSMISSION.............................................................................................. 75 Storage, New Transmission.............................................................................................................. 75 Storage, One Year -- Without Oil....................................................................................................... 75 Storage, One Year With Oil (normally in a vehicle chassis)............................................................................. 75 Restoring Transmission to Service...................................................................................................... 75 STRUCTURES......................................................................................................................................... 77 STRUCTURAL COMPONENTS.......................................................................................................................... 79 LADDERS.................................................................................................................................... 79 Removal................................................................................................................................ 79 Installation........................................................................................................................... 79 RIGHT HAND DECK................................................................................................................................ 80 Removal.................................................................................................................................... 80 Installation............................................................................................................................... 80 CENTER AND LEFT HAND DECK COMPONENTS........................................................................................................... 81 FUEL TANK...................................................................................................................................... 82 Removal.................................................................................................................................... 82 Installation............................................................................................................................... 82 DUMP BODY...................................................................................................................................... 83 Removal.................................................................................................................................... 83 Installation............................................................................................................................... 84 BODY PADS.................................................................................................................................. 85 Adjustment............................................................................................................................. 86 BODY GUIDE................................................................................................................................. 86 BODY-UP RETENTION CABLE.................................................................................................................... 86 BODY POSITION INDICATOR.................................................................................................................... 87 ROCK EJECTORS (Type I)..................................................................................................................... 87 Inspection............................................................................................................................. 87 HOIST LIMIT SWITCHES....................................................................................................................... 87 ROCK EJECTORS (Type II).................................................................................................................... 88 ENGINE, FUEL, COOLING AND AIR CLEANER.............................................................................................................. 89 POWER MODULE................................................................................................................................... 91 PREPARATION................................................................................................................................ 91 Removal................................................................................................................................ 91 Installation........................................................................................................................... 95 COOLING SYSTEM................................................................................................................................. 97 COOLING SYSTEM DESCRIPTION................................................................................................................. 97 RADIATOR................................................................................................................................... 98 Removal................................................................................................................................ 98 Installation...........................................................................................................................100 RADIATOR FILLING PROCEDURE.................................................................................................................100 POWER TRAIN....................................................................................................................................101 ALTERNATOR REMOVAL PROCEDURE...............................................................................................................101 Removal (Komatsu SSDA16V160 or SDA16V160 Engine).......................................................................................101 ENGINE/ALTERNATOR MATING...................................................................................................................103 General Instructions...................................................................................................................103 MEASURING PROCEDURE....................................................................................................................103 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine......................................................................105 ENGINE.....................................................................................................................................106 Removal................................................................................................................................106 Service................................................................................................................................106 Installation...........................................................................................................................106 AIR FILTRATION SYSTEM..........................................................................................................................107 AIR CLEANER................................................................................................................................107 Operation..............................................................................................................................107 General Service Information............................................................................................................107 MAIN FILTER ELEMENT........................................................................................................................107 Removal................................................................................................................................107 Installation...........................................................................................................................108 SAFETY FILTER ELEMENT......................................................................................................................109 Removal................................................................................................................................109 Installation...........................................................................................................................109 AIR INTAKE TROUBLESHOOTING.................................................................................................................109 AIR CLEANER ASSEMBLY CLEANING..............................................................................................................109 Main Filter Cleaning...................................................................................................................109 Precleaner Section Cleaning............................................................................................................110 ELECTRICAL SYSTEM (24 VDC. NON-PROPULSION..........................................................................................................113 24VDC ELECTRIC SUPPLY SYSTEM...................................................................................................................115 ELECTRICAL SYSTEM DESCRIPTION..............................................................................................................115 BATTERY....................................................................................................................................115 Maintenance and Service................................................................................................................115 Troubleshooting........................................................................................................................115 BATTERY CHARGING SYSTEM (Niehoff)..........................................................................................................117 General Description....................................................................................................................117 TROUBLESHOOTING PROCEDURES (On-Truck)......................................................................................................117 Preliminary Checks.....................................................................................................................118 Test Setup.............................................................................................................................118 Test Procedure.........................................................................................................................118 Regulator Bypass Test..................................................................................................................119 ON VEHICLE TROUBLESHOOTING GUIDE - SELF ENERGIZED ALTERNATOR...................................................................................120 ALTERNATOR ELECTRICAL CONDITION - Low Voltage - High Voltage - No Voltage..................................................................120 PRELIMINARY PROCEDURES.................................................................................................................120 LOW VOLTAGE OUTPUT.....................................................................................................................120 HIGH VOLTAGE OUTPUT....................................................................................................................120 NO VOLTAGE OUTPUT......................................................................................................................120 TOOLS AND EQUIPMENT:...................................................................................................................120 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:.......................................................................................120 Low Maintenance Types:.............................................................................................................120 Maintenance Free types:............................................................................................................121 High-Cycle Maintenance Free Types:.................................................................................................121 DEFINITIONS............................................................................................................................121 ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized........................................................................................122 NO ALTERNATOR OUTPUT.......................................................................................................................122 STATIC TEST - ENGINE OFF, KEY ON, BATTERY SWITCH ON....................................................................................122 GO TO ALTERNATOR”......................................................................................................................122 GO TO “R” TERMINAL ON ALTERNATOR.......................................................................................................122 RE-TEST CHARGING CIRCUIT FOR OPERATION with ENGINE RUNNING.............................................................................122 GO TO REGULATOR (IF REQUIRED)..........................................................................................................123 GO TO REGULATOR CONNECTOR ON ALTERNATOR................................................................................................123 24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE)..............................................................................................124 OPERATION..............................................................................................................................124 Pressure Switch....................................................................................................................125 Check Valve........................................................................................................................125 Timer Solenoid.....................................................................................................................125 MAINTENANCE........................................................................................................................125 Prelube System Operation Checks....................................................................................................125 Check Valve........................................................................................................................125 Timer Solenoid.....................................................................................................................125 Troubleshooting Prelube Starter Circuit............................................................................................126 24 VDC ELECTRIC START SYSTEM...................................................................................................................128 CRANKING MOTORS............................................................................................................................128 OPERATION..............................................................................................................................128 Removal............................................................................................................................128 Installation.......................................................................................................................128 CRANKING MOTOR TROUBLESHOOTING.............................................................................................................129 Preliminary Inspection.................................................................................................................129 No-Load Test...........................................................................................................................129 Interpreting Results of Tests..........................................................................................................129 Disassembly............................................................................................................................130 Cleaning and Inspection................................................................................................................132 Armature Servicing.....................................................................................................................132 Field Coil Checks......................................................................................................................132 Field Coil Removal.....................................................................................................................132 Solenoid Checks........................................................................................................................133 Test...................................................................................................................................133 Assembly...............................................................................................................................134 Bearing Replacement:...................................................................................................................134 Motor Assembly:........................................................................................................................134 Pinion Clearance.......................................................................................................................135 Removal................................................................................................................................135 Installation...........................................................................................................................135 Coil Test..............................................................................................................................136 24VDC ELECTRICAL SYSTEM COMPONENTS.............................................................................................................137 ALARM INDICATING DEVICE (AID)..............................................................................................................137 Coolant Level/Flasher Card.............................................................................................................137 Temperature/Latch Card.................................................................................................................137 Oil Level Card.........................................................................................................................138 Temperature Card.......................................................................................................................138 Hot Switch Inverter Card (Slot 4)......................................................................................................138 Hot Switch Inverter Card (Slot 3)......................................................................................................138 Diode Matrix Without Sound Card........................................................................................................138 Diode Matrix With Sound Card...........................................................................................................138 BODY-UP SWITCH.............................................................................................................................138 Adjustment.............................................................................................................................139 Service................................................................................................................................139 HOIST LIMIT SWITCH.........................................................................................................................139 Adjustment.............................................................................................................................139 Service................................................................................................................................139 BATTERY EQUALIZER..........................................................................................................................140 Troubleshooting........................................................................................................................140 GROUND LEVEL SHUTDOWN......................................................................................................................140 24 VOLT RELAY AND DIODE BOARDS.............................................................................................................141 RELAY BOARDS...............................................................................................................................141 Description............................................................................................................................141 SERVICE....................................................................................................................................142 RELAY BOARD COMPONENTS.....................................................................................................................143 Relay Board 1 Turn Signal..............................................................................................................143 Relay Board 2 Payload Meter (Optional).................................................................................................143 Relay Board 3 Stop Lights..............................................................................................................144 Relay Board 4 Parking Brake............................................................................................................144 Relay Board 5 Head Lights..............................................................................................................144 Relay Board 6 Auxiliary Panel..........................................................................................................145 DIODE BOARD 1..............................................................................................................................146 Diode Testing..........................................................................................................................146 CIRCUIT BREAKERS...........................................................................................................................146 ELECTRICAL PROPULSION COMPONENTS...................................................................................................................149 ELECTRICAL PROPULSION COMPONENTS...............................................................................................................155 GENERAL SYSTEM DESCRIPTION.................................................................................................................155 CONTROL SYSTEM.............................................................................................................................155 System Operation.......................................................................................................................156 FL275 Panel............................................................................................................................157 CARD REPLACEMENT...........................................................................................................................158 Removal................................................................................................................................158 Installation...........................................................................................................................158 Card Repair............................................................................................................................158 Panel Wiring...........................................................................................................................158 COMPUTER DESCRIPTION.......................................................................................................................159 Microprocessor.........................................................................................................................159 Download Capability....................................................................................................................159 SOFTWARE...................................................................................................................................159 Base Monitor Program...................................................................................................................159 Runtime Monitor Program - OBJ Running Code.............................................................................................159 Configuration Software - CFG...........................................................................................................160 PTU - Portable Test Unit Code..........................................................................................................160 System Regulation......................................................................................................................160 Propulsion.............................................................................................................................161 Retarding..............................................................................................................................161 TWO-DIGIT DISPLAY PANEL....................................................................................................................162 The Coded Number.......................................................................................................................162 Events.................................................................................................................................162 Frames.................................................................................................................................163 Windows................................................................................................................................163 System Categories......................................................................................................................163 Limits On Resetting Faults.............................................................................................................163 NA Faults..............................................................................................................................164 Event Sequence.........................................................................................................................164 Resetting Events.......................................................................................................................164 Event Descriptions.....................................................................................................................164 Subcode Descriptions...................................................................................................................164 2-DIGIT DISPLAY PANEL SUBCODES.............................................................................................................172 PORTABLE TEST UNIT (PTU).......................................................................................................................175 DESCRIPTION................................................................................................................................175 Operational Hints......................................................................................................................175 SOFTWARE INSTALLATION PREPARATION..........................................................................................................176 HARD DISK SPACE REQUIREMENTS...............................................................................................................176 SOFTWARE INSTALLATION ON PTU...............................................................................................................176 PTU/Truck Communication Problems...........................................................................................................177 THE MAIN MENU..............................................................................................................................178 Quit Menu..............................................................................................................................178 PTU Talk To Truck......................................................................................................................178 View PTU Saved Files...................................................................................................................178 List Stat Data Files...................................................................................................................178 Truck Setup (CFG)......................................................................................................................178 Select Truck Setup.....................................................................................................................178 Change PTU Password....................................................................................................................178 Update CFG Version.....................................................................................................................178 CONFIGURATION (CFG) FILE CONVERSION........................................................................................................180 Conversion Procedure...................................................................................................................180 Convert Old CFG files for New software.................................................................................................181 STATEX CONFIGURATION FILES.................................................................................................................184 0) Source Directory: . . ..............................................................................................................184 1) Select A Truck Configuration . . ...................................................................................................185 2) View Truck Configuration: Data Curves . . ..........................................................................................186 3) Change/View Serial and Model Numbers . . ...........................................................................................187 4) View Options . . ...................................................................................................................187 5) Change/View Truck Specifics . . ....................................................................................................189 6) Change/View Overspeeds . . .........................................................................................................191 7) Save a Truck Configuration, filename: . . ..........................................................................................192 8) Save Directory: . . ................................................................................................................193 CHANGE PTU PASSWORD........................................................................................................................194 PROGRAMMING THE TRUCK......................................................................................................................195 Connect PTU to the Truck...............................................................................................................195 Select Configuration File..............................................................................................................195 Activate The PTU Mode..................................................................................................................195 Check Object Code Version..............................................................................................................196 Download Configuration Files...........................................................................................................197 Date And Time..........................................................................................................................198 Event Data.............................................................................................................................199 Statistical Data.......................................................................................................................201 View Counters..........................................................................................................................201 View Profiles..........................................................................................................................201 Upload Statistical Data To A File......................................................................................................201 Statistical Data Codes - Counters......................................................................................................202 STATISTICAL DATA CODES - COUNTERS..........................................................................................................203 STATISTICAL DATA CODES - PROFILES..........................................................................................................208 TRUCK SPECIFIC INFORMATION.................................................................................................................212 Temporary Truck Settings...................................................................................................................213 MISCELLANEOUS FEATURES.....................................................................................................................214 Saving Data............................................................................................................................214 PTU Abbreviations......................................................................................................................215 Other Menu Selections..................................................................................................................215 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS.................................................................................................216 ALTERNATOR.................................................................................................................................216 ELECTRIC WHEEL MOTORS......................................................................................................................216 RETARDING GRIDS............................................................................................................................216 ELECTRONIC ACCELERATOR AND RETARD PEDALS...................................................................................................216 Removal................................................................................................................................216 Installation...........................................................................................................................216 Disassembly............................................................................................................................217 Reassembly.............................................................................................................................217 COOLING BLOWER WARNING SYSTEM..............................................................................................................217 Operation..............................................................................................................................217 Test...................................................................................................................................217 Removal................................................................................................................................218 Installation...........................................................................................................................218 ELECTRICAL CONTROL CABINET.................................................................................................................219 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS.....................................................................................224 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III.........................................................................................225 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE................................................................................................227 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE............................................................................................231 GENERAL INFORMATION....................................................................................................................231 COMMUNICATIONS PORT CHECK..............................................................................................................232 PTU Hookup.........................................................................................................................232 4.0 SEQUENCE TESTS - (ENGINE NOT ON)...................................................................................................233 Preparation and Setup..............................................................................................................233 CONTROL SYSTEM SELF-TEST...............................................................................................................234 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT...............................................................................................234 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT.................................................................................................235 PTU Setup..........................................................................................................................235 4.3 REVERSER AND PROPULSION CONTACTORS CHECK...........................................................................................236 4.4 NOT USED...........................................................................................................................237 4.5 RETARD CONTACTORS OPERATION CHECK..................................................................................................237 4.6 GROUND FAULT SENSING CHECK.........................................................................................................237 4.7 GROUND FAULT IN RETARD OPERATION CHECK.............................................................................................238 4.8 OVERRIDE OPERATION CHECK...........................................................................................................238 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK..................................................................................................239 4.10 OVERSPEED RETARD OPERATION CHECK..................................................................................................239 4.11 HOIST INTERLOCK OPERATION CHECK...................................................................................................240 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK..........................................................................................240 Return to Main Menu................................................................................................................240 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL...............................................................................241 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU......................................................................................241 5.2 DIGITAL INPUT CHECKS...............................................................................................................242 5.3 DIGITAL OUTPUT CHECKS..............................................................................................................243 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL.......................................................................................247 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU...........................................................................................247 6.2 ANALOG INPUT CHECKS................................................................................................................248 6.3 FREQUENCY INPUT CHECKS.............................................................................................................252 Return to Main Menu................................................................................................................253 7.0 SPEED EVENT CHECKS.................................................................................................................253 Preparation and Setup..............................................................................................................253 Setup PTU..........................................................................................................................253 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK............................................................................254 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK.................................................................254 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK................................................................254 7.4 OTHER SPEED EVENTS CHECKS..........................................................................................................254 Return to Main Menu................................................................................................................254 8.0 RETARD SPEED CONTROL SYSTEM CHECK..................................................................................................255 Preparation and Setup..............................................................................................................255 Setup PTU..........................................................................................................................255 8.1 OVERSPEED PICKUP AND DROPOUT CHECK.................................................................................................255 8.2 RETARD POT MAXIMUM SETTING CHECK...................................................................................................255 8.3 RETARD POT MINIMUM SETTING CHECK...................................................................................................255 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL.................................................................................256 Return to Main Menu................................................................................................................256 9.0 LOAD TEST USING TRUCK RETARD GRIDS.................................................................................................256 Setup and Preparation..............................................................................................................256 PTU Setup..........................................................................................................................256 9.1 LOAD TEST..........................................................................................................................257 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING............................................................................................257 Setup PTU..........................................................................................................................257 10.1 RETARD CHECK......................................................................................................................258 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT.......................................................................................259 11.1 BRAKE SYSTEM INTERLOCKS CHECK.....................................................................................................259 Preparation........................................................................................................................259 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT............................................................................................259 11.3 SYNC TRANSFORMER CHECKOUT.........................................................................................................260 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT........................................................................................260 11.5 BATTERY BOOST ADJUSTMENT..........................................................................................................260 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST.......................................................................................260 11.7 MOTOR ROTATION TEST...............................................................................................................261 11.8 GROUND FAULT CHECKS...............................................................................................................261 12.0 MISCELLANEOUS CHARTS..............................................................................................................262 12.1 WHEEL MOTOR GEAR RATIOS...........................................................................................................262 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS....................................................................................................263 12.3 ENGINE OPTIONS....................................................................................................................264 DRIVE AXLE, SPINDLES AND WHEELS....................................................................................................................267 TIRES AND RIMS.................................................................................................................................269 FRONT TIRES AND RIMS.......................................................................................................................269 Removal................................................................................................................................269 Installation...........................................................................................................................270 REAR TIRES AND RIMS........................................................................................................................271 Removal................................................................................................................................271 Installation...........................................................................................................................272 RIM........................................................................................................................................273 Tire Removal...........................................................................................................................273 RIM AND TIRE PREPARATION...................................................................................................................273 LUBRICANTS.................................................................................................................................274 TIRE INSTALLATION..........................................................................................................................274 FRONT WHEEL HUB AND SPINDLE....................................................................................................................277 WHEEL HUB AND SPINDLE ASSEMBLY.............................................................................................................277 Removal................................................................................................................................277 Spindle Pusher Tool Usage..............................................................................................................278 Installation...........................................................................................................................279 Disassembly............................................................................................................................281 Cleaning and Inspection................................................................................................................281 Assembly...............................................................................................................................282 Wheel Bearing Adjustment (Tire Removed)................................................................................................284 Wheel Bearing Adjustment (Tire mounted)................................................................................................284 STEERING CYLINDERS AND TIE ROD.............................................................................................................286 Spherical Bearing Wear Limits..........................................................................................................286 Removal................................................................................................................................287 Installation...........................................................................................................................287 Bearing Replacement....................................................................................................................287 TOE-IN ADJUSTMENT..........................................................................................................................289 REAR AXLE HOUSING ATTACHMENT...................................................................................................................291 PIVOT PIN..................................................................................................................................291 Removal................................................................................................................................291 Installation...........................................................................................................................291 PIVOT EYE BEARING..........................................................................................................................292 Disassembly............................................................................................................................292 Assembly...............................................................................................................................292 PIVOT EYE REPAIR...........................................................................................................................293 Removal................................................................................................................................293 Disassembly............................................................................................................................293 Assembly...............................................................................................................................293 Installation...........................................................................................................................293 ANTI-SWAY BAR..............................................................................................................................294 Removal................................................................................................................................294 Installation...........................................................................................................................294 Disassembly............................................................................................................................294 Cleaning and Inspection................................................................................................................294 Assembly...............................................................................................................................294 REAR AXLE HOUSING..............................................................................................................................295 REAR AXLE HOUSING..........................................................................................................................295 Removal................................................................................................................................295 Installation...........................................................................................................................295 WHEEL MOTOR................................................................................................................................295 Removal................................................................................................................................295 Cleaning and Inspection................................................................................................................296 Installation...........................................................................................................................296 Maximum Cap Screw Usage................................................................................................................296 FRONT SUSPENSION...............................................................................................................................299 Removal....................................................................................................................................299 MAXIMUM CAPSCREW USAGE.....................................................................................................................301 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)........................................................................................303 Bearing Structure Removal..............................................................................................................303 Bearing Structure Installation.........................................................................................................303 MAJOR SUSPENSION REBUILD...................................................................................................................304 Disassembly............................................................................................................................304 Assembly...............................................................................................................................305 PRESSURE TEST..............................................................................................................................306 REAR SUSPENSIONS...............................................................................................................................307 Removal....................................................................................................................................307 Installation...............................................................................................................................309 Disassembly................................................................................................................................311 Cleaning and Inspection....................................................................................................................311 Assembly...................................................................................................................................311 PRESSURE TEST..............................................................................................................................312 OILING AND CHARGING PROCEDURE..................................................................................................................313 GENERAL....................................................................................................................................313 EQUIPMENT LIST.............................................................................................................................313 HYDRAIR® CHARGING KIT......................................................................................................................313 Installation of Charging Kit...........................................................................................................313 Removal of Charging Kit................................................................................................................314 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS..........................................................................................314 FRONT SUSPENSION...........................................................................................................................315 Front Suspension Oiling................................................................................................................315 Front Suspension Nitrogen Charging.....................................................................................................316 REAR SUSPENSION............................................................................................................................317 Rear Suspension Oiling.................................................................................................................317 Rear Suspension Nitrogen Charging......................................................................................................318 OIL AND NITROGEN SPECIFICATIONS CHART..........................................................................................................320 HYDRAIR II SUSPENSIONS.............................................................................................................................297 FRONT SUSPENSION...............................................................................................................................299 FRONT SUSPENSION...........................................................................................................................299 REMOVAL................................................................................................................................299 INSTALLATION...........................................................................................................................300 TURN-OF-THE-NUT"...................................................................................................................302 MINOR REPAIR (LOWER BEARING STRUCTURE AND SALES)...........................................................................................303 BEARING STRUCTURE REMOVAL..............................................................................................................303 BEARING STRUCTURE INSTALLATION.........................................................................................................303 MAJOR ASSEMBLY REBUILD.....................................................................................................................304 DISASSEMBLY............................................................................................................................304 ASSEMBLY...............................................................................................................................305 PRESSURE TEST..........................................................................................................................306 REAR SUSPENSION................................................................................................................................307 REMOVAL....................................................................................................................................307 INSTALLATION...............................................................................................................................309 DISASSEMBLY............................................................................................................................311 ASSEMBLY...............................................................................................................................311 PRESSURE TEST..........................................................................................................................312 OILING AND CHARGING PROCEDURES.................................................................................................................313 GENERAL....................................................................................................................................313 EQUIPMENT LIST.............................................................................................................................313 FRONT SUSPENSION...........................................................................................................................315 FRONT SUSPENSION OILING................................................................................................................315 FRONT SUSPENSION NITROGEN CHARGING.....................................................................................................316 REAR SUSPENSION............................................................................................................................317 REAR SUSPENSION OILING.................................................................................................................317 REAR SUSPENSION NITROGEN CHARGING......................................................................................................318 OIL AND NITROGEN SPECIFICATIONS................................................................................................................320 BRAKE CIRCUIT......................................................................................................................................321 BRAKE CIRCUIT..................................................................................................................................323 SERVICE BRAKE CIRCUIT OPERATION............................................................................................................323 SECONDARY BRAKING AND AUTOMATIC APPLY......................................................................................................325 PARKING BRAKE CIRCUIT......................................................................................................................325 BRAKE LOCK CIRCUIT.........................................................................................................................326 WARNING CIRCUIT............................................................................................................................326 BRAKE CIRCUIT COMPONENT SERVICE................................................................................................................329 BRAKE VALVE................................................................................................................................329 Rebuild Criteria.......................................................................................................................329 Removal................................................................................................................................329 DISASSEMBLY................................................................................................................................332 Cleaning and Inspection................................................................................................................334 ASSEMBLY...................................................................................................................................334 Actuator Base Threaded Inserts.........................................................................................................334 Boot and Cap...........................................................................................................................334 Valve Body Seal Installation...........................................................................................................335 Regulator Sleeve O-Ring Installation...................................................................................................335 Actuator Plunger O-ring Installation...................................................................................................335 Assembly of Valve......................................................................................................................336 DIFFERENTIAL PRESSURE SWITCH...............................................................................................................337 Disassembly............................................................................................................................337 Cleaning and Inspection................................................................................................................337 Assembly...............................................................................................................................337 VALVE BENCH TEST AND ADJUSTMENT............................................................................................................338 Test Set Up Procedure..................................................................................................................339 Brake Valve Output Pressure Adjustment.................................................................................................339 Differential Pressure Switch Test......................................................................................................339 Final Test and Adjustment..............................................................................................................340 Installation Of Brake Pedal Actuator Assembly to Brake Valve...........................................................................341 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal).......................................................342 Installation of Retard Pedal To Brake Pedal............................................................................................342 HYDRAULIC BRAKE ACCUMULATORS...............................................................................................................343 Brake Accumulator Bleed Down Procedure.................................................................................................343 Removal................................................................................................................................343 Installation...........................................................................................................................343 Disassembly............................................................................................................................343 Cleaning and Inspection................................................................................................................344 Assembly...............................................................................................................................345 Charging Procedure.....................................................................................................................346 BRAKE MANIFOLD.............................................................................................................................347 Removal................................................................................................................................347 Removal................................................................................................................................347 Installation...........................................................................................................................348 Disassembly............................................................................................................................348 Cleaning and Inspection................................................................................................................348 Assembly...............................................................................................................................348 BRAKE CIRCUIT CHECK-OUT PROCEDURE..............................................................................................................349 EQUIPMENT REQUIRED.........................................................................................................................351 INITIAL SYSTEM SET-UP......................................................................................................................352 PARKING BRAKE..............................................................................................................................352 BRAKE SYSTEM CHECK-OUT.....................................................................................................................352 Failure Modes Check-Out................................................................................................................353 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING..................................................................................................355 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET..................................................................................359 KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET......................................................................................360 ROCKWELL WHEEL SPEED FRONT DISC BRAKES.........................................................................................................361 BRAKE CALIPER..............................................................................................................................361 Removal................................................................................................................................361 Installation...........................................................................................................................362 Piston Removal.........................................................................................................................363 Installation...........................................................................................................................363 Caliper Cleaning and Inspection........................................................................................................363 BRAKE LINING...............................................................................................................................365 Replacement............................................................................................................................365 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE..............................................................................................366 Front Brake Conditioning...................................................................................................................366 Temporary Disconnect Procedures For Rear Brakes............................................................................................366 BRAKE BLEEDING PROCEDURES..................................................................................................................368 ROCKWELL ARMATURE SPEED REAR DISC BRAKES.......................................................................................................369 REAR BRAKES................................................................................................................................369 CALIPER, DISC, AND PARKING BRAKE...........................................................................................................369 Caliper, Disc, And Parking Brake Removal...............................................................................................369 Caliper, Disc, And Parking Brake Installation..........................................................................................370 CALIPER, DISC, AND PARKING BRAKE REMOVAL...................................................................................................372 Caliper, Disc, And Parking Brake Installation..........................................................................................373 CALIPER PISTON ASSEMBLY....................................................................................................................374 Piston Assembly Removal................................................................................................................374 Piston Assembly Inspection.............................................................................................................374 Piston Assembly Installation...........................................................................................................374 FUNCTIONAL TEST OF PISTON ASSEMBLY.........................................................................................................375 Return Spring Force....................................................................................................................375 Built-In Clearance.....................................................................................................................375 Grip Force.............................................................................................................................376 Grip Force Measurement.................................................................................................................377 Spring Force Measurement...............................................................................................................378 Disassembly of Piston Assembly.........................................................................................................379 Assembly of Piston Assembly............................................................................................................380 BENCH TEST.................................................................................................................................380 BRAKE LINING...............................................................................................................................381 Replacement............................................................................................................................381 Brake Pad Conditioning (Burnishing) Procedure..........................................................................................383 Conditioning (Burnishing) Rear Brakes..................................................................................................383 General................................................................................................................................383 BLEEDING PROCEDURE.........................................................................................................................384 Temporary Disconnect Procedures for Disabling Front Brakes.............................................................................384 TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Models 630E and 685E Komatsu Trucks.........................................385 TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Model 830E Komatsu Trucks...................................................385 ROCKWELL DISC PARKING BRAKE....................................................................................................................387 CALIPER STYLE IDENTIFICATION...............................................................................................................387 PARK BRAKE CALIPER.........................................................................................................................388 Park Brake Caliper Removal.............................................................................................................388 Park Brake Caliper Installation........................................................................................................388 Parking Brake Adjustment (SCL70).......................................................................................................388 Parking Brake Adjustment (SCL15).......................................................................................................390 Park Brake Caliper Disassembly.........................................................................................................391 Cleaning and Inspection................................................................................................................392 Park Brake Caliper Assembly............................................................................................................393 PARK BRAKE LINING REPLACEMENT..............................................................................................................393 PARK BRAKE BURNISH PROCEDURE...............................................................................................................393 Lining Conditioning....................................................................................................................393 BRAKE BLEEDING PROCEDURE...................................................................................................................393 HYDRAULIC SYSTEM...................................................................................................................................395 HYDRAULIC SYSTEM...............................................................................................................................397 HYDRAULIC SYSTEM OPERATION.................................................................................................................397 COMPONENT DESCRIPTION......................................................................................................................398 HYDRAULIC SYSTEM COMPONENT REPAIR..............................................................................................................401 HOIST PUMP.................................................................................................................................401 Removal................................................................................................................................401 Installation...........................................................................................................................402 Disassembly............................................................................................................................403 INSPECTION OF PARTS........................................................................................................................406 Assembly...............................................................................................................................407 HYDRAULIC TANK.............................................................................................................................412 Filling Instructions...................................................................................................................412 Removal................................................................................................................................412 Installation...........................................................................................................................413 HYDRAULIC TANK STRAINERS...................................................................................................................413 Removal................................................................................................................................413 Inspect and Clean......................................................................................................................413 Installation...........................................................................................................................413 HYDRAULIC TANK BREATHERS...................................................................................................................414 HOIST CIRCUIT FILTERS......................................................................................................................414 FILTER ELEMENT REPLACEMENT.................................................................................................................415 Removal................................................................................................................................415 INDICATOR SWITCH...........................................................................................................................415 STEERING CIRCUIT...............................................................................................................................417 STEERING CIRCUIT OPERATION.................................................................................................................417 COMPONENT DESCRIPTION......................................................................................................................418 STEERING CONTROL UNIT......................................................................................................................418 FLOW AMPLIFIER.............................................................................................................................418 No Steer...............................................................................................................................420 Steering Left..........................................................................................................................422 Steering Right.........................................................................................................................424 No Steer, External Shock Load..........................................................................................................426 BLEED DOWN MANIFOLD........................................................................................................................428 ACCUMULATORS...............................................................................................................................429 Low Precharge Warning Switch...........................................................................................................429 HIGH PRESSURE FILTER.......................................................................................................................429 STEERING/BRAKE PUMP........................................................................................................................429 Operation..............................................................................................................................430 PRINCIPLE OF OPERATION.....................................................................................................................432 Full Pump Volume:......................................................................................................................432 Half Pump Volume:......................................................................................................................432 STEERING CIRCUIT COMPONENT REPAIR..............................................................................................................435 BLEED DOWN MANIFOLD........................................................................................................................435 Removal................................................................................................................................435 Installation...........................................................................................................................435 ACCUMULATOR................................................................................................................................436 Removal................................................................................................................................436 Installation...........................................................................................................................437 Disassembly............................................................................................................................438 Cleaning and Inspection................................................................................................................438 Assembly...............................................................................................................................439 TESTING....................................................................................................................................439 FLOW AMPLIFIER.............................................................................................................................441 Removal................................................................................................................................441 Installation...........................................................................................................................441 Disassembly............................................................................................................................442 Reassembly.............................................................................................................................445 STEERING CONTROL UNIT......................................................................................................................446 Removal................................................................................................................................446 Spline Inspection......................................................................................................................446 Installation...........................................................................................................................446 Disassembly............................................................................................................................447 Cleaning and Inspection................................................................................................................448 Assembly...............................................................................................................................448 STEERING CYLINDER..........................................................................................................................452 Disassembly............................................................................................................................452 Inspection and Cleaning................................................................................................................452 Assembly...............................................................................................................................452 STEERING CIRCUIT FILTER....................................................................................................................453 FILTER ELEMENT REPLACEMENT.............................................................................................................453 Removal............................................................................................................................454 Installation.......................................................................................................................454 INDICATOR SWITCH...................................................................................................................454 STEERING AND BRAKE PUMP....................................................................................................................455 Removal................................................................................................................................455 Installation...........................................................................................................................455 Disassembly............................................................................................................................457 Control Piston Group...................................................................................................................457 Valve Plate Group......................................................................................................................457 Rotating Group.........................................................................................................................458 Swashblock Group.......................................................................................................................458 Driveshaft Group.......................................................................................................................458 INSPECTION.................................................................................................................................458 Control Piston Group...................................................................................................................458 Valve Plate Group......................................................................................................................458 Rotating Group.........................................................................................................................458 Swashblock Group.......................................................................................................................462 Driveshaft Group.......................................................................................................................462 Compensator Block and Unloader Module..................................................................................................462 Stroke Adjuster Assembly...............................................................................................................462 ASSEMBLY...................................................................................................................................462 Swashblock Group.......................................................................................................................462 Control Piston Group...................................................................................................................464 Valve Plate Group......................................................................................................................464 HOIST CIRCUIT..................................................................................................................................467 HOIST CIRCUIT OPERATION....................................................................................................................467 COMPONENT DESCRIPTION......................................................................................................................468 HOIST PUMP.................................................................................................................................468 HIGH PRESSURE FILTERS......................................................................................................................468 HOIST VALVE................................................................................................................................469 HOIST PILOT VALVE..........................................................................................................................470 HOIST-UP LIMIT SOLENOID....................................................................................................................470 PILOT OPERATED CHECK VALVE.................................................................................................................470 COUNTERBALANCE VALVE MANIFOLD..............................................................................................................470 FLOAT POSITION OF PILOT VALVE AND BODY ON FRAME............................................................................................472 POWER UP OPERATION (Figure 7-6)............................................................................................................474 HOLD OPERATION (Figure 7-7)................................................................................................................476 POWER DOWN OPERATION (Figure 7-8)..........................................................................................................478 FLOAT OPERATION (Figure 7-9)...............................................................................................................480 HOIST CIRCUIT COMPONENT REPAIR.................................................................................................................483 HOIST VALVE................................................................................................................................483 Relieve pressure before disconnecting hydraulic lines. Tighten all connections securely before applying pressure.......................483 Hydraulic fluid escaping under pressure can have sufficient force to enter a person's body by penetrating the skin and cause ser.......483 Removal................................................................................................................................483 Installation...........................................................................................................................483 O-Ring Replacement.....................................................................................................................484 INLET SECTION..............................................................................................................................484 Disassembly............................................................................................................................484 Cleaning and Inspection................................................................................................................485 Assembly...............................................................................................................................486 SPOOL SECTION..............................................................................................................................486 Disassembly............................................................................................................................486 Cleaning and Inspection................................................................................................................488 Assembly...............................................................................................................................488 HOIST PILOT VALVE..........................................................................................................................489 Removal................................................................................................................................489 Installation...........................................................................................................................489 Disassembly............................................................................................................................489 Cleaning and Inspection................................................................................................................491 Assembly...............................................................................................................................491 BODY UP LIMIT SOLENOID.....................................................................................................................492 PILOT OPERATED CHECK VALVE.................................................................................................................492 COUNTERBALANCE VALVE MANIFOLD..............................................................................................................492 HOIST CYLINDERS............................................................................................................................492 Removal................................................................................................................................492 Installation...........................................................................................................................493 Disassembly............................................................................................................................495 Cleaning and Inspection................................................................................................................496 ASSEMBLY OF QUILL AND CYLINDER.............................................................................................................497 Quill Installation.....................................................................................................................497 Installation Of Check Balls And Plugs In Quill.........................................................................................498 Assembly of Cylinder...................................................................................................................499 DISABLED TRUCK DUMPING PROCEDURE...........................................................................................................500 HOOKUP.....................................................................................................................................500 DUMPING PROCEDURE..........................................................................................................................500 HYDRAULIC CHECK-OUT PROCEDURE..................................................................................................................501 STEERING AND BRAKE PUMP....................................................................................................................501 Pressure Check And Adjustment Procedure................................................................................................501 BLEEDDOWN MANIFOLD.....................................................................................................................502 SHOCK & SUCTION VALVES.....................................................................................................................503 Shock & Suction Valve Settings.............................................................................................................503 LEAKAGE TESTS..............................................................................................................................503 Steering Control Unit & Flow Amplifier.................................................................................................504 Bleed Down Manifold....................................................................................................................505 TROUBLESHOOTING CHART (Steering Circuit).......................................................................................................506 TROUBLESHOOTING CHART (Steering Pump)..........................................................................................................509 TROUBLESHOOTING CHART (Flow Amplifier).........................................................................................................512 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE....................................................................................................514 HYDRAULIC SYSTEM FLUSHING PROCEDURE............................................................................................................517 OPTIONS AND SPECIAL TOOLS..........................................................................................................................519 FIRE CONTROL SYSTEM (MANUAL)...................................................................................................................521 Operation..................................................................................................................................521 Inspection and Maintenance.................................................................................................................521 Recharging Procedures......................................................................................................................522 ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM............................................................................................523 SYSTEM ADJUSTMENT..........................................................................................................................523 PUMP.......................................................................................................................................523 Removal................................................................................................................................523 Disassembly............................................................................................................................523 Inspection.............................................................................................................................525 Assembly...............................................................................................................................525 Installation...........................................................................................................................526 BLOWER DRIVE MOTOR.........................................................................................................................526 Removal................................................................................................................................527 Disassembly............................................................................................................................527 Inspection Of Parts....................................................................................................................528 Assembly...............................................................................................................................528 Installation...........................................................................................................................529 BLOWER BEARING REPAIR......................................................................................................................529 Removal................................................................................................................................529 Replacement............................................................................................................................529 Assembly...............................................................................................................................530 AIR CLEANER................................................................................................................................530 Assembly...............................................................................................................................530 Removal................................................................................................................................530 Washing Air Cleaner....................................................................................................................530 Assembly...............................................................................................................................530 WIGGINS QUICK FILL FUEL SYSTEM.................................................................................................................531 FUEL RECEIVER..............................................................................................................................531 TANK BREATHER VALVE........................................................................................................................532 Removal................................................................................................................................532 Installation...........................................................................................................................532 Disassembly............................................................................................................................532 Assembly...............................................................................................................................532 LEFT SIDE FILL.............................................................................................................................533 BUCKEYE QUICK FUEL SYSTEM......................................................................................................................535 FUEL TANK BREATHER VALVE...................................................................................................................535 Maintenance............................................................................................................................535 Filter Service.........................................................................................................................535 Disassembly............................................................................................................................535 Inspection.............................................................................................................................535 Assembly...............................................................................................................................535 FUEL RECEIVER..............................................................................................................................536 ENGINE COOLANT HEATER..........................................................................................................................537 Maintenance................................................................................................................................537 HEATING ELEMENT............................................................................................................................537 Removal................................................................................................................................537 Installation...........................................................................................................................537 THERMOSTAT.................................................................................................................................538 Removal................................................................................................................................538 Installation...........................................................................................................................538 SPECIAL TOOLS..................................................................................................................................539 AIR CONDITIONING SYSTEM........................................................................................................................545 Environmental Impact.......................................................................................................................545 OPERATOR CAB AIR CONDITIONING..............................................................................................................546 PRINCIPLES OF REFRIGERATION................................................................................................................546 Air Conditioning.......................................................................................................................546 Refrigeration - The Act Of Cooling.....................................................................................................547 The Refrigeration Cycle................................................................................................................547 AIR CONDITIONER SYSTEM COMPONENTS..........................................................................................................548 Compressor (Refrigerant Pump)..........................................................................................................548 Service Valves.........................................................................................................................548 Condenser..............................................................................................................................548 Expansion Block Valve..................................................................................................................549 Evaporator.............................................................................................................................549 ELECTRICAL CIRCUIT.........................................................................................................................550 Thermostat.............................................................................................................................550 Compressor Clutch......................................................................................................................550 Trinary™ Switch........................................................................................................................551 SYSTEM SERVICING...........................................................................................................................552 SYSTEM OIL.................................................................................................................................553 Handling and Reusing PAG Oil...........................................................................................................553 Oil Quantity...........................................................................................................................553 Replacing Oil After Servicing the System...............................................................................................553 Setting Up a New Compressor............................................................................................................553 REFRIGERANT................................................................................................................................554 Recycled Refrigerant...................................................................................................................554 Reclaimed Refrigerant..................................................................................................................554 Refrigerant Quantity...................................................................................................................554 R-134a Refrigerant Containers..........................................................................................................554 SERVICE TOOLS AND EQUIPMENT................................................................................................................555 Recovery/Recycle Station...............................................................................................................555 Leak Detector..........................................................................................................................555 Service Valves.........................................................................................................................556 Vacuum Pump............................................................................................................................556 Manifold Gauge Set.....................................................................................................................557 Installing Manifold Gauge Set..........................................................................................................558 Purging Air From Service Hoses.........................................................................................................559 Stabilizing the AC System..............................................................................................................560 SYSTEM PERFORMANCE TEST....................................................................................................................560 SYSTEM LEAK TESTING........................................................................................................................561 Electronic leak detector...............................................................................................................561 Tracer dyes............................................................................................................................561 Soap and water.........................................................................................................................561 SYSTEM REPAIR..............................................................................................................................562 System Cleaning........................................................................................................................562 Hoses and Fittings.....................................................................................................................562 Lines..................................................................................................................................562 Expansion Valve........................................................................................................................562 Receiver-Drier.........................................................................................................................563 Thermostat.............................................................................................................................563 Compressor.............................................................................................................................563 Clutch.................................................................................................................................563 Servicing the Compressor Clutch........................................................................................................564 Pulley Removal.........................................................................................................................566 Clutch Coil Check......................................................................................................................566 Pulley Installation....................................................................................................................566 Clutch Assembly Installation...........................................................................................................567 RECOVERING AND RECYCLING THE REFRIGERANT...................................................................................................568 Performing the Recovery Cycle..........................................................................................................568 Performing the Recycling Procedure.....................................................................................................568 Evacuating and Charging the AC System..................................................................................................568 EVACUATING THE SYSTEM......................................................................................................................569 CHARGING THE AC SYSTEM.....................................................................................................................570 TROUBLESHOOTING............................................................................................................................571 Pre-Diagnosis Checks...................................................................................................................571 Preparing For Diagnosis................................................................................................................571 Preliminary Steps......................................................................................................................571 System Performance Test................................................................................................................571 Diagnosis Of Gauge Readings And System Performance.....................................................................................572 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM................................................................................................579 RADIATOR SHUTTERS..............................................................................................................................581 OPERATION..................................................................................................................................581 Hydraulic Circuit......................................................................................................................581 Electrical Circuit:....................................................................................................................582 MAINTENANCE AND REPAIR.....................................................................................................................582 TROUBLESHOOTING............................................................................................................................584 Hydraulic Troubleshooting..............................................................................................................587 Electrical Troubleshooting.............................................................................................................589 Electrical troubleshooting.............................................................................................................590 PAYLOAD METER II - ON BOARD WEIGHING SYSTEM....................................................................................................593 GENERAL INFORMATION........................................................................................................................595 Haul Cycles............................................................................................................................595 LIGHTS, SWITCHES AND COMPONENTS............................................................................................................596 TIPS FOR OPERATION.........................................................................................................................597 EXTERNAL DISPLAY LIGHTS....................................................................................................................597 THEORY OF OPERATION........................................................................................................................598 Basic Description......................................................................................................................598 Inclinometer...........................................................................................................................598 Linkage Factor.........................................................................................................................598 Gain Factor............................................................................................................................599 Brake Lock.............................................................................................................................599 Sources of Error.......................................................................................................................599 Typical Data From Service Check Mode...................................................................................................599 Example Calculation of Payload.........................................................................................................600 Viewing Payload Calculation Inputs.....................................................................................................600 Checking the Gain......................................................................................................................601 Adjusting the Gain.....................................................................................................................601 TYPES OF DATA STORED.......................................................................................................................602 Cycle Data.............................................................................................................................602 Engine ON/OFF Data.....................................................................................................................603 Fault Codes and Warning Data...........................................................................................................603 Engine Operation.......................................................................................................................604 Total Payload and Total Number of Cycles...............................................................................................604 Other Data.............................................................................................................................604 OPERATOR FUNCTIONS.....................................................................................................................605 Using the Operator Load Counter........................................................................................................605 Viewing the Operator Load Counter......................................................................................................605 Clearing the Operator Load Counter.....................................................................................................605 Dimming the Lights on the Display......................................................................................................605 INITIAL SETUP OF PAYLOAD METER.............................................................................................................606 Switch Settings........................................................................................................................606 Checking the Operator Check Mode.......................................................................................................607 Checking the Service Check Mode........................................................................................................607 Checking the Gt setting:...............................................................................................................608 Checking the Inclinometer Settings.....................................................................................................608 Calibrating a Truck....................................................................................................................608 DISPLAYS AT START-UP.......................................................................................................................609 Normal Operation.......................................................................................................................609 SETUP AND MAINTENANCE......................................................................................................................610 Setting The Speed Limit................................................................................................................610 Setting the Option Code................................................................................................................610 Setting The Machine I.D. Code..........................................................................................................611 Setting The Operator I.D. Code.........................................................................................................611 Setting The Time and Date..............................................................................................................611 DOWNLOAD OF INFORMATION....................................................................................................................612 DISPLAY OF FAULT CODES.....................................................................................................................612 Monitoring Input Signals...............................................................................................................616 Service Check Mode.....................................................................................................................616 UP FACTOR - PAYLOAD CALCULATION GAIN.......................................................................................................617 PL MODE -LOAD CALCULATION TIMING...........................................................................................................617 FINAL GEAR RATIO SELECTION.................................................................................................................618 BATTERY REPLACEMENT PROCEDURE..............................................................................................................619 Replacing the Battery..................................................................................................................619 After Replacing the Battery............................................................................................................620 SUSPENSION PRESSURE SENSOR.................................................................................................................620 Removal................................................................................................................................620 Installation...........................................................................................................................621 INCLINOMETER...............................................................................................................................621 Removal................................................................................................................................621 Installation...........................................................................................................................621 Adjustment.............................................................................................................................621 PAYLOAD METER BACK PANEL...................................................................................................................622 CONNECTIONS................................................................................................................................623 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE..............................................................................................624 PAYLOAD CIRCUIT NUMBERS....................................................................................................................625 TROUBLESHOOTING............................................................................................................................626 COMMON PROBLEMS........................................................................................................................626 Suspension Charging................................................................................................................626 Symptom Table......................................................................................................................627 Missing Body-Up Signal.............................................................................................................627 Missing Speed Signal...............................................................................................................628 F-18: Alternator R-Terminal, Oil Pressure Signals..................................................................................628 Shorted 18v Sensor Power Supply (930E).............................................................................................628 FAULT TREE DIAGNOSIS...................................................................................................................629 Payload Lights Won't Illuminate....................................................................................................629 Red, Amber or Green Payload Light Does Not Illuminate..............................................................................630 Cannot Download - PC Communications................................................................................................631 PC Communications Configuration....................................................................................................632 F.CAL: Payload Meter Won't Calibrate...............................................................................................633 F-20: Sensor Power Fault...........................................................................................................634 F-21, F-25: Left Front Pressure Sensor.............................................................................................636 F-22, F-26: Right Front Pressure Sensor............................................................................................636 F-23, F-27: Left Rear Pressure Sensor..............................................................................................636 F-24, F-28: Right Rear Pressure Sensor.............................................................................................636 F-31, F-32: Inclinometer...........................................................................................................638 Body Up Input......................................................................................................................640 Brake Lock Input...................................................................................................................641 Speed Signal.......................................................................................................................642 Adjusting the Speed Sensor.........................................................................................................642 CONNECTORS AND PRESSURE SENSORS........................................................................................................644 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM................................................................................................647 Menu Functions.........................................................................................................................650 Using Scope............................................................................................................................650 Log File Information...................................................................................................................650 Connections to Payload Meter II™.......................................................................................................651 USING SCOPE................................................................................................................................652 Monitoring Inputs Using Scope..........................................................................................................652 Monitoring Suspension Charging Using Scope.............................................................................................652 Pressure Sensor Dummy Loads............................................................................................................655 GAIN ADJUSTMENT WORKSHEET..................................................................................................................656 OPERATOR'S CAB.....................................................................................................................................657 TRUCK CAB......................................................................................................................................659 Description................................................................................................................................659 Removal....................................................................................................................................660 Installation...............................................................................................................................661 CAB DOOR.......................................................................................................................................662 Removal....................................................................................................................................662 Installation...............................................................................................................................662 Door Adjustment............................................................................................................................662 Door Jamb Bolt Adjustment..................................................................................................................662 Door Handle Plunger Adjustment.............................................................................................................664 Replace Door Glass.........................................................................................................................665 Replace Door Window Regulator..............................................................................................................669 Replace Door Handle or Latch Assembly......................................................................................................669 Door and Door Hinge Seal Replacement.......................................................................................................670 Door Opening Seal Removal..................................................................................................................670 Installation...............................................................................................................................670 GLASS REPLACEMENT..............................................................................................................................671 ADHESIVE-BONDED WINDOWS....................................................................................................................671 Replacement Procedure..................................................................................................................671 WINDSHIELD & REAR GLASS....................................................................................................................672 Removal................................................................................................................................672 Installation...........................................................................................................................673 CAB COMPONENTS.................................................................................................................................675 WINDSHIELD WIPER...........................................................................................................................675 Removal................................................................................................................................675 Installation...........................................................................................................................675 WINDSHIELD WASHER..........................................................................................................................676 Operation..............................................................................................................................676 Service................................................................................................................................676 OPERATOR COMFORT...............................................................................................................................677 ELECTRICAL CIRCUITS........................................................................................................................680 OPERATOR CONTROLS AND EQUIPMENT................................................................................................................683 STEERING WHEEL AND CONTROLS................................................................................................................684 HORN BUTTON................................................................................................................................684 TILT / TELESCOPE LEVER.....................................................................................................................684 TURN SIGNAL / HEADLIGHT DIMMER.............................................................................................................684 STEERING COLUMN............................................................................................................................684 Removal................................................................................................................................684 Installation...........................................................................................................................685 SERVICE BRAKE PEDAL........................................................................................................................686 DYNAMIC RETARDER PEDAL.....................................................................................................................686 OPTIONAL - DUAL FUNCTION / SINGLE PEDAL....................................................................................................686 THROTTLE PEDAL.............................................................................................................................686 HEATER / AIR CONDITIONER VENTS.............................................................................................................686 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS..........................................................................................687 DEFROSTER VENT CONTROL SWITCH..............................................................................................................687 OUTSIDE/INSIDE AIR CONTROL SWITCH..........................................................................................................687 HEAT VENT CONTROL SWITCH...................................................................................................................687 TEMPERATURE CONTROL KNOB...................................................................................................................687 FAN CONTROL KNOB...........................................................................................................................687 HEATER/AIR CONDITIONER SELECTOR SWITCH.....................................................................................................687 HEATER/AIR CONDITIONER VENTS...............................................................................................................687 INSTRUMENT PANEL...........................................................................................................................688 GRADE/SPEED WARNING CHART..................................................................................................................688 HOIST CONTROL LEVER........................................................................................................................690 INSTRUMENT PANEL AND INDICATOR LIGHTS......................................................................................................693 CONTROL SYMBOLS............................................................................................................................693 INSTRUMENT PANEL...........................................................................................................................694 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 3-6)........................................................................................695 INDICATOR LIGHT SYMBOLS....................................................................................................................700 LUBRICATION AND SERVICE............................................................................................................................705 LUBRICATION AND SERVICE........................................................................................................................707 LUBRICATION SPECIFICATIONS CHARTS..........................................................................................................707 SERVICE CAPACITIES.....................................................................................................................707 HYDRAULIC TANK SERVICE AND FILING INSTRUCTIONS.........................................................................................707 RADIATOR FILING PROCEDURE..............................................................................................................708 ANTI-FREEZE SPECIFICATIONS.............................................................................................................708 LUBRICATION CHART - OIL GREASE SPECIFICATIONS..........................................................................................709 10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS.........................................................................................710 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................................................................712 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................................713 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................................714 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................................716 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................717 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................718 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................719 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................................................719 AUTOMATIC LUBRICATION SYSTEM...................................................................................................................721 GENERAL DESCRIPTION........................................................................................................................721 SYSTEM COMPONENTS..........................................................................................................................723 SYSTEM OPERATION...........................................................................................................................724 INJECTOR OPERATION.....................................................................................................................726 GENERAL INSTRUCTIONS.......................................................................................................................727 SYSTEM CHECKOUT............................................................................................................................729 PUMP REBUILD...........................................................................................................................730 SYSTEM TROUBLESHOOTING CHART...........................................................................................................733 PREVENTATIVE MAINTENANCE PROCEDURES........................................................................................................736 MOTORIZED WHEEL MAINTENANCE SCHEDULE...........................................................................................................737 AXLE BOX...................................................................................................................................737 ARMATURE AREA..............................................................................................................................738 AT TIRE CHANGE - FOR ALL MOTORIZED WHEELS..................................................................................................738 GENERATOR / ALTERNATOR.....................................................................................................................739 GRID BLOWER MOTOR..........................................................................................................................739 CONTROL EQUIPMENT CHECKS...................................................................................................................739 AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM.............................................................................................740 VEHICLE OPERATIONS TESTS...................................................................................................................740 ALPHABETICAL INDEX.................................................................................................................................741 SYSTEM SCHEMATICS..................................................................................................................................745 HYDRAULIC HOIST/STEERING SCHEMATIC.............................................................................................................747 HYDRAULIC BRAKE SCHEMATIC (STATEX III; LAPS)...................................................................................................748 STATEX III FL-275 PANEL........................................................................................................................749 STATEX III POWER & EXCITATION SCHEMATIC........................................................................................................779 STATEX III ELECTRICAL CONTROL CABINET COMPONENT LOCATION.......................................................................................782
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