Komatsu 830E Dump Truck Shop Manual SN A30625-A30649 – PDF DOWNLOAD

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Komatsu 830E Dump Truck Shop Manual

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Komatsu 830E Dump Truck Shop Manual 

Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 830E
Serial Number: A30625-A30649
Book Code: CEBM006300
Language: English
Pages:731
File Format: Portable Document Format (PDF)

KOMATSU 830E DUMP TRUCK SHOP MANUAL SN A30625-A30649 – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu 830E Dump Truck Shop Manual 

FOREWORD:

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.

TABLE OF CONTENTS:

Komatsu 830E Dump Truck Shop Manual 

MAIN MENU...........................................................................  0
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
	STORAGE PROCEDURES.............................................................. 57
STRUCTURES.......................................................................... 77
	STRUCTURAL COMPONENTS........................................................... 79
		LADDERS..................................................................... 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
		DUMP BODY................................................................... 83
			REMOVAL................................................................. 83
			INSTALLATION............................................................ 83
		BODY PADS................................................................... 85
			ADJUSTMENT.............................................................. 86
		BODY GUIDE.................................................................. 86
		BODY-UP RETENTION CABLE..................................................... 86
		BODY POSITION INDICATOR..................................................... 87
		ROCK EJECTORS............................................................... 87
			INSPECTION.............................................................. 87
		HOIST LIMIT SWITCHES........................................................ 87
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
			ENGINE/ALTERNATOR MATING................................................103
				MEASURING PROCEDURE.................................................103
			JOINING ALTERNATOR AND ENGINE...........................................105
		ENGINE......................................................................106
			REMOVAL.................................................................106
			INSTALLATION............................................................106
	AIR FILTERATION SYSTEM..........................................................107
		AIR CLEANER.................................................................107
			OPERATION...............................................................107
			GENERAL SERVICE INFORMATION.............................................107
		MAIN FILTER ELEMENT.........................................................107
		SAFETY FILTER ELEMENT.......................................................108
			AIR INTAKE TROUBLESHOOTING..............................................109
		AIR CLEANER ASSEMBLY CLEANING...............................................109
			MAIN FILTER ELEMENT CLEANING............................................109
			PRECLEANER SECTION CLEANING.............................................110
ELECTRIC SYSTEM (24 VDC. NON-PROPULSION.............................................113
	24VDC ELECTRIC SUPPLY SYSTEM....................................................115
		ELECTRICAL SYSTEM DESCRIPTION...............................................115
		BATTERY - MAINTENANCE AND SERVICE...........................................115
			TROUBLESHOOTING.........................................................115
		BATTERY CHARGING SYSTEM (NIEHOFF)...........................................117
			GENERAL DESCRIPTION.....................................................117
			TROUBLESHOOTING PROCEDURES..............................................117
			ON VEHICLE TROUBLESHOOTING GUIDE........................................120
			ADVANCED SYSTEM TROUBLESHOOTING.........................................122
		24VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE)................................124
			OPERATION...............................................................124
			MAINTENANCE.............................................................125
			TROUBLESHOOTING.........................................................126
		24VOLT ELECTRIC START SYSTEM, CRANKING MOTORS...............................128
			TROUBLESHOOTING.........................................................129
	24VDC ELECTRICAL SYSTEM COMPONENTS..............................................137
		ALARM INDICATING DEVICE (A.I.D. SYSTEM).....................................137
		BODY UP SWITCH..............................................................138
		HOIST LIMIT SWITCH..........................................................139
		BATTERY EQUALIZER...........................................................140
		GROUND LEVEL SHUTDOWN.......................................................140
ELECTRIC PROPULSION AND CONTROL.....................................................149
	ELECTRICAL PROPULSION COMPONENTS................................................151
		GENERAL SYSTEM DESCRIPTION..................................................151
		CONTROL SYSTEM..............................................................151
		17FL275 PANEL...............................................................153
			COMPUTER DESCRIPTION....................................................155
			SOFTWARE................................................................155
		2-DIGIT DISPLAY PANEL.......................................................158
			EVENTS..................................................................158
			FRAMES..................................................................159
			WINDOWS.................................................................159
				EVENT CODE DESCRIPTIONS (TABLE I)...................................161
				SUBCODE DESCRIPTIONS (TABLE II).....................................168
		PORTABLE TEST UNIT (PTU)....................................................171
			DESCRIPTION.............................................................171
			SOFTWARE INSTALLATION PREPARATION.......................................172
				THE MAIN MENU.......................................................174
				PTU SOFTWARE MENU TREE..............................................175
				CONFIGURATION (CFG) FILE CONVERSION.................................176
			STATEX CONFIGURATION FILES..............................................182
			PROGRAMMING THE TRUCK...................................................193
				PTU HOOKUP..........................................................193
				DOWNLOAD CONFIGURATION FILES........................................195
			EVENTS DATA.............................................................197
			STATISTICAL DATA........................................................199
				STATISTICAL DATA CODES - COUNTERS (TABLE III).......................201
				STATISTICAL DATA CODES - PROFILES (TABLE IV)........................206
			TRUCK SPECIFIC INFORMATION..............................................210
			TEMPORARY TRUCK SETTINGS................................................211
			MISCELLANEOUS SOFTWARE FEATURES.........................................212
				SAVING DATA.........................................................212
				PTU ABBREVIATIONS...................................................213
	MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..................................215
		ALTERNATOR..................................................................215
		ELECTRIC WHEEL MOTORS.......................................................215
		RETARDING GRIDS.............................................................215
		ELECTRIC ACCELERATOR AND RETARD CONTROL.....................................215
		COOLING BLOWER WARNING SYSTEM...............................................217
		ELECTRICAL CONTROL CABINET..................................................218
		STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS..........................223
	ELECTRICAL CHECKOUT PROCEDURE...................................................225
		SEE PAGES E3-1 AND E3-2 FOR INDEX OF CHECKOUT PROCEDURE.....................225
		GENERAL INFORMATION.........................................................227
		COMMUNICATIONS PORT CHECK...................................................228
			PTU HOOKUP..............................................................228
		1. SEQUENCE TESTS - (ENGINE NOT RUNNING)....................................230
			1.1. THROTTLE SYSTEM CHECK AND ADJUSTMENT...............................230
				1.1.1 ELECTRONIC THROTTLE SYSTEM....................................231
				1.1.2 ELECTRONIC THROTTLE SYSTEM FUEL ENHANCEMENT ("FUEL SAVER")....232
			1.2 RETARD SYSTEM AND ADJUSTMENT - ELECTRONIC PEDAL SYSTEM..............235
			1.3 REVERSER AND PROPULSION CONTRACTORS CHECK ..........................237
			1.4 PROPULSION LOCKOUT TEST (DDEC, MTU ENGINES).........................238
			1.5 RETARD CONTARCTORS OPERATION CHECK..................................239
			1.6 GROUND FAULT SENSING CHECK..........................................239
			1.7 GROUND FLOOR AND RETARD OPERATION CHECK.............................239
			1.8 OVERRIDE OPERATION CHECK............................................240
			1.9 ANTI-REVERSAL FUNCTION (AR) CHECK...................................241
			1.10 OVERSPEED RETARD OPERATION CHECK...................................241
			1.11 HOIST INTERLOCK OPERATION CHECK....................................242
			1.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK...........................243
		2. DIGITAL INPUT/OUTPUT SIGNAL TESTS - FL275 CARD PANEL.....................245
			2.1 SETUP MANUL DIGITAL INPUT/OUTPUT TEST ON PTU........................245
			2.2 DIGITAL INPUT CHECKS................................................246
			2.3 DIGITAL OUTPUT CHECKS...............................................248
		3. ANALOG INPUT SIGNALS TESTS - FL275 CARD PANEL............................251
			3.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU............................251
			3.2 ANALOG INPUT CHECKS.................................................252
			3.3 FREQUENCY INPUT CHECKS..............................................258
		4. SPEED EVENT CHECKS.......................................................260
			4.1 SINGLE SPEED OVERSPEED - OVERSPEED SETTINGS CHECK...................261
			4.2 EMPTY TRUCK - 2 SPEED OVERSPEED SETTINGS CHECK......................261
			4.3 LOADED TRUCK - 2 SPEED OVERSPEED SETTINGS CHECK.....................261
			4.4 OTHER SPEED EVENTS CHECKS...........................................261
		5. RETARD SPEED CONTROL SYSTEM CHECK........................................263
			5.1 OVERSPEED PICKUP AND DROPOUT CHECK..................................263
			5.2 RETARD POT MAXIMUM SETTINGS CHECK...................................264
			5.3 RETARD POT MINIMUM SETTINGS CHECK...................................264
			5.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL..................264
		6. LOAD TEST USING TRUCK RETARD GRIDS.......................................265
		7. MOTOR FIELD CURRENT CHECK IN RETARDING...................................267
		8. MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT..............................268
			8.1 BRAKE SYSTEM INTERLOCKS CHECK.......................................268
			8.2 BLOWER LOW PRESSURE SWITCH ADJUSTMENT...............................269
			8.3 SYNC TRANSFORMER CHECKOUT...........................................269
			8.4 POWER CONTRACTOR POSITION SENSOR ADJUSTMENT.........................269
			8.5 BATTERY BOOST ADJUSTMENT............................................270
			8.6 ISOLATION AMPLIFIER & VOLTAGE MODULE TEST...........................270
			8.7 MOTOR ROTATION TEST.................................................272
			8.8 GROUND FAULT CHECKS.................................................272
		9. OPTIONAL PAYLOAD METER CHECK - OUT PROCEDURE.............................273
		10. MISCELLANEOUS CHARTS....................................................274
			10.1 WHEEL MOTOR GEAR RATIOS............................................274
			10.2 MAXIMUM ALLOWABLE TRUCK SPEEDS.....................................275
			10.3 ENGINE OPTIONS.....................................................276
DRIVE AXLE, SPINDLES AND WHEELS.....................................................277
	TIRES AND RIMS..................................................................279
		FRONT TIRES AND RIMS........................................................279
			REMOVAL.................................................................279
			INSTALLATION............................................................280
		REAR TIRES AND RIMS.........................................................280
			REMOVAL.................................................................280
			INSTALLATION............................................................281
		RIM.........................................................................282
			TIRE REMOVAL............................................................282
			TIRE INSTALLATION.......................................................283
	FRONT WHEEL HUB AND SPINDLE ASSEMBLY............................................285
		WHEEL HUB AND SPINDLE ASSEMBLY..............................................285
			REMOVAL.................................................................285
			INSTALLATION............................................................287
			DISASSEMBLY.............................................................287
			CLEANING AND INSPECTION.................................................288
			ASSEMBLY................................................................288
			WHEEL BEARING ADJUSTMENT................................................290
			WHEEL BEARING ADJUSTMENT (TIRE MOUNTED).................................291
	STEERING CYLINDERS AND TIRE ROD.................................................292
		STEERING CYLINDERS AND TIRE ROD.............................................292
			REMOVAL.................................................................292
			INSTALLATION............................................................292
		BEARING REPLACEMENT.........................................................292
		TOE-IN ADJUSTMENT (TIRE MOUNTED)............................................294
	REAR AXLE HOUSING ATTACHMENT....................................................295
		PIVOT PIN...................................................................295
			REMOVAL.................................................................295
			INSTALLATION............................................................295
		PIVOT EYE BEARING...........................................................296
			DISASSEMBLY.............................................................296
			ASSEMBLY................................................................296
		ANTI-SWAY BAR...............................................................298
			REMOVAL.................................................................298
			INSTALLATION............................................................298
			DISASSEMBLY.............................................................298
			CLEANING AND INSPECTION.................................................298
			ASSEMBLY................................................................298
	REAR AXLE HOUSING...............................................................299
		REAR AXLE HOUSING...........................................................299
			REMOVAL.................................................................299
			INSTALLATION............................................................299
		WHEEL MOTOR.................................................................299
			REMOVAL.................................................................299
			CLEANING AND INSPECTION.................................................300
			INSTALLATION............................................................300
HYDRAIR II SUSPENSIONS..............................................................301
	FRONT SUSPENSION................................................................303
		FRONT SUSPENSION............................................................303
			REMOVAL.................................................................303
			INSTALLATION............................................................304
				TURN-OF-THE-NUT"....................................................306
		MINOR REPAIR (LOWER BEARING STRUCTURE AND SALES)............................307
			BEARING STRUCTURE REMOVAL...............................................307
			BEARING STRUCTURE INSTALLATION..........................................307
		MAJOR ASSEMBLY REBUILD......................................................308
			DISASSEMBLY.............................................................308
			ASSEMBLY................................................................309
			PRESSURE TEST...........................................................310
	REAR SUSPENSION.................................................................311
		REMOVAL.....................................................................311
		INSTALLATION................................................................313
			DISASSEMBLY.............................................................315
			ASSEMBLY................................................................316
			PRESSURE TEST...........................................................316
	OILING AND CHARGING PROCEDURES..................................................317
		GENERAL.....................................................................317
		EQUIPMENT LIST..............................................................317
		FRONT SUSPENSION............................................................318
			FRONT SUSPENSION OILING.................................................318
			FRONT SUSPENSION NITROGEN CHARGING......................................319
		REAR SUSPENSION.............................................................320
			REAR SUSPENSION OILING..................................................320
			REAR SUSPENSION NITROGEN CHARGING.......................................321
	OIL AND NITROGEN SPECIFICATIONS.................................................322
BRAKE CIRCUIT.......................................................................323
	BRAKE CIRCUIT...................................................................325
		SERVICE BRAKE CIRCUIT OPERATION.............................................325
		SECONDARY BRAKING AND AUTOMATIC APPLY.......................................327
		PARKING BRAKE CIRCUIT.......................................................327
		BRAKE LOCK CIRCUIT..........................................................328
		WARMING CIRCUIT.............................................................328
		BRAKE VALVE FULL CUT-AWAY...................................................329
		BRAKE VALVE PARTIAL CUT-AWAY................................................330
	BRAKE CIRCUIT COMPONENT SERVICE.................................................331
		BRAKE VALVE.................................................................331
			REMOVAL ................................................................331
			INSTALLATION............................................................333
			DISASSEMBLY.............................................................334
			CLEANING AND INSPECTION.................................................336
			ASSEMBLY................................................................336
			DIFFERENTIAL PRESSURE SWITCH............................................339
			VALVE BENCH TEST AND ADJUSTMENT.........................................340
			INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE............343
			BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL..........344
		HYDRAULIC BRAKE ACCUMULATORS................................................345
	BRAKE CIRCUIT CHECK-OUT PROCEDURE...............................................349
		BRAKE CIRCUIT AND BRAKE  VALUE TROUBLESHOOTING..............................355
		HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET.......................359
	ROCKWELL WHEEL SPEED FRONT DISC BRAKES..........................................361
		BRAKE CALIPER...............................................................361
		BRAKE LINING................................................................365
		BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE...............................366
		TEMPORARY DISCONNECT PROCEDURES FOR REAR BRAKES.............................366
		BRAKE BLEEDING PROCEDURE....................................................368
	ROCKWELL ARMATURE SPEED REAR DISC BRAKES........................................369
		REAR BRAKES.................................................................369
		CALIPER, DISC AND  PARKING BRAKE............................................369
		CALIPER PISTON ASSEMBLY.....................................................374
		BENCH TEST..................................................................380
		BRAKE LINING................................................................381
		BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE...............................383
		BRAKE BLEEDING PROCEDURE....................................................384
	ROCKWELL DISC PARKING BRAKE.....................................................387
		CALIPER STYLE IDENTIFICATION (SCL15 VS. SCL70)..............................387
		PARK BRAKE CALIPER .........................................................388
			REMOVAL.................................................................388
			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...........................................................393
			REPLACEMENT.............................................................393
			PARK BRAKE BURNISH PROCEDURE............................................393
		BRAKE BLEEDING PROCEDURE....................................................393
HYDRAULIC SYSTEM....................................................................395
	HYDRAULIC SYSTEM................................................................397
		COMPONENT DESCRIPTION.......................................................398
	HYDRAULIC SYSTEM COMPONENT REPAIR...............................................401
		HOIST PUMP..................................................................401
		HYDRAULIC TANK .............................................................412
			HYDRAULIC TANK STRAINERS................................................413
			HOIST CIRCUIT FILTERS...................................................414
	STEERING CIRCUIT................................................................417
		STEERING CIRCUIT OPERATION..................................................417
		COMPONENT DESCRIPTION.......................................................418
			STEERING CONTROL UNIT...................................................418
			FLOW AMPLIFIER..........................................................418
			BLEED DOWN MANIFOLD.....................................................428
			ACCUMULATOR.............................................................429
			STEERING CIRCUIT FILTER.................................................429
			STEERING/BRAKE PUMP.....................................................429
	STEERING CIRCUIT COMPONENT REPAIR...............................................435
		BLEED DOWN MANIFOLD.........................................................435
		ACCUMULATOR.................................................................436
			STEERING ACCUMULATOR CHARGING PROCEDURE.................................440
		FLOW AMPLIFIER..............................................................441
		STEERING CONTROL UNIT.......................................................446
		STEERING CYLINDER...........................................................452
		STEERING CIRCUIT FILTER.....................................................453
		STEERING AND BRAKE PUMP.....................................................455
	HOIST CIRCUIT...................................................................467
		HOIST CIRCUIT OPERATION.....................................................467
		COMPONENT DESCRIPTION.......................................................468
			HYDRAULIC TANK..........................................................468
			HOIST PUMP..............................................................468
			HIGH PRESSURE FILTERS...................................................468
			HOIST VALUE.............................................................469
			HOIST PILOT VALUE.......................................................470
			HOIST-UP LIMIT SOLENOID.................................................470
			PILOT OPERATED CHECK VALVE..............................................470
			COUNTERBALANCE VALVE MANIFOID...........................................470
		HOIST SYSTEM OPERATION MODES................................................471
	HOIST CIRCUIT COMPONENT REPAIR..................................................483
		HOIST VALUE.................................................................483
			INLET SECTION ..........................................................484
			SPOOL SECTION...........................................................486
		HOIST PILOT VALVE...........................................................489
		BODY - UP LIMIT SOLENOID....................................................492
		PILOT OPERATED CHECK VALUE..................................................492
		COUNTERBALANCE VALVE MANIFOID...............................................492
		HOIST CYLINDERS.............................................................492
	HYDRAULIC CHECKOUT PROCEDURE....................................................501
		STEERING AND BRAKE PUMP.....................................................501
		BLEED DOWN MANIFOLD.........................................................502
		SHOCK & SUCTION VALUES......................................................503
		LEAKAGE TESTS...............................................................503
		TROUBLESHOOTING CHART ......................................................506
			STEERING CIRCUIT........................................................506
			STEERING PUMP...........................................................509
			FLOW AMPLIFIER..........................................................512
		CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE.................................514
			TROUBLESHOOTING GUIDE (HOIST PUMP)......................................516
		HYDRAULIC SYSTEM FLUSHING PROCEDURE.........................................517
OPTIONS AND SPECIAL TOOLS...........................................................519
	ANSULFIRE CONTROL SYSTEM MANUAL (M02004)........................................521
		OPERATION...................................................................521
		INSPECTION AND MAINTENANCE..................................................521
		RECHARGING PROCEDURES.......................................................522
	ALTERNATOR AND WHEELMOTOR COLING AIR FILTER SYSTEM (M04002).....................523
		SYSTEM ADJUSTMENT...........................................................523
		PUMP........................................................................523
		BLOWER DRIVE MOTOR..........................................................526
		BLOWER BEARING REPAIR.......................................................529
		AIR CLEANER.................................................................530
	WIGGINS QUICK FILL FUEL SYSTEM..................................................531
		FUEL RECEIVER...............................................................531
		TANK BREATHER VALVE.........................................................532
	BUCKEYE QUICK FILL FUEL SYSTEM (M05003).........................................535
		TANK BREATHER VALVE.........................................................535
		FUEL RECEIVER...............................................................536
	ENGINE COOLANT HEATER (M07001)..................................................537
		HEATING ELEMENT.............................................................537
		THERMOSTAT..................................................................538
	SPECIAL TOOL GROUP (M08005).....................................................539
	HEATER/AIR CONDITIONING SYSTEM (M09010).........................................543
		ENVIORNMENTAL IMPACT........................................................543
		GENERAL INFORMATION.........................................................544
			OPERATOR CAB AIR CONDITIONING...........................................544
		PRINCIPLES OF REFRIGERATION.................................................544
		AIR CONDITIONER SYSTEM COMPONENTS...........................................546
		ELECTRICAL CIRCUIT..........................................................548
		SYSTEM SERVICING............................................................549
		SERVICE TOOLS AND EQUIPMENT.................................................550
		MANIFOLD GAUGE SET..........................................................552
		SYSTEM PERFORMANCE TEST.....................................................557
		SYSTEM LEAK TESTING.........................................................557
		SYSTEM REPAIR...............................................................558
		EVACUATING THE SYSTEM.......................................................560
		TROUBLESHOOTING.............................................................561
		PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..............................569
	PAYLOAD METER II (M20007).......................................................571
		GENERAL INFORMATION.........................................................573
		LIGHTS, SWIITCHES, AND COMPONENTS...........................................574
		TIPS FOR OPERATION..........................................................575
		EXTERNAL DISPLAY LIGHTS.....................................................575
		THEORY OF OPERATION.........................................................576
			BASIC DESCRIPTION.......................................................576
			LINKAGE FACTOR..........................................................576
			BRAKE LOCK..............................................................577
			SOURCES OF ERROR........................................................577
			TYPICAL DATA FROM SERVICE CHECK MODE....................................577
			EXAMPLE CALCULATION OF PAYLOAD..........................................578
			CALCULATION OF THE LOAD.................................................578
		TYPES OF DATA STORED........................................................579
			CYCLE DATA..............................................................579
			ENGINE ON/OFF DATA......................................................580
			FAULT CODES AND WARNING DATA............................................580
			ENGINE OPERATION........................................................581
			TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES................................581
			OTHER DATA..............................................................581
		OPERATOR FUNCTIONS..........................................................582
			USING THE OPERATOR LOAD COUNTER.........................................582
				DESCRIPTION.........................................................582
				VIEWING THE OPERATOR LOAD COUNTER...................................582
				CLEANING THE OPERATOR LOAD COUNTER..................................582
			DIMMING THE LIGHTS ON THE DISPLAY.......................................582
		INITIAL SETUP OF PAYLOAD METER..............................................583
			SWITCH SETTINGS.........................................................583
			CHECKING THE OPERATOR LOAD COUNTER......................................583
			CHECKING THE SERVICE LOAD COUNTER.......................................584
				SETTING "UP:00" ....................................................584
				SETTING "PL:00" ....................................................584
			CHECKING THE Gt SETTING.................................................584
			CHECKING THE INCINOMETER SETTINGS.......................................584
			CALIBRATING A TRUCK.....................................................585
		DISPLAYS AT START-UP........................................................586
		SETUP AND MAINTENANCE.......................................................587
			SETTINGS THE SPEED LIMIT................................................587
			SETTING THE OPTION CODE.................................................587
			SETTING THE MACHINE I.D.................................................587
			SETTING THE OPERATOR I.D................................................588
			SETTING THE TIME AND DATE...............................................588
		DOWNLOAD OF PAYLOAD AND FAULT CODES.........................................588
		DISPLAY OF FAULT CODES......................................................589
		CHARTS OF ERROR CODES AND OTHER INFORMATION.................................590
		SERVICE CHECK MODE..........................................................592
			MONITORING INPUT SIGNALS................................................592
			UP FACTOR - PAYLOAD CALCULATION GAIN....................................593
			PL MODE - LOAD CALCULATION TIMING.......................................593
		FINAL GEAR RATIO SELECTION..................................................594
		BATTERY REPLACEMENT PROCEDURE...............................................595
			REPLACING THE BATTERY...................................................595
			AFTER REPLACING THE BATTERY.............................................596
		SUSPENSION PRESSURE SENSOR..................................................596
			REMOVAL.................................................................596
			INSTALLATION............................................................597
		INCLINOMETER................................................................597
			REMOVAL.................................................................597
			INSTALLATION............................................................597
		SCOREBOARD..................................................................598
			DESCRIPTION.............................................................598
			MAKING CONNECTIONS......................................................598
			WIRING DIAGRAM..........................................................599
			NORMAL OPERATION OF THE SCOREBOARD......................................600
		PAYLOAD METER BACK PANEL....................................................600
			CONNECTIONS (AMP PIN IDENTIFICATION)....................................601
		PAYLOAD CIRCUIT NUMBERS.....................................................602
		PAYLOAD METER II RE-INITIALIZATION PROCEDURE................................603
OPERATOR'S CAB......................................................................605
	TRUCK CAB.......................................................................607
		TRUCK CAB...................................................................607
			DESCRIPTION.............................................................607
			REMOVAL.................................................................608
			INSTALLATION............................................................609
		CAB DOOR....................................................................610
			REMOVAL.................................................................610
			INSTALLATION............................................................610
			DOOR ADJUSTMENT.........................................................610
			DOOR HANDLE PLUNGER ADJUSTMENT..........................................612
			REPLACE DOOR GLASS......................................................613
			REPLACE DOOR WINDOW REGULATOR...........................................617
			DOOR AND HINGE SEAL REPLACEMENT.........................................618
			GLASS REPLACEMENT.......................................................619
				ADHESIVE-BONDED WINDOWS.............................................619
				WINDSHIELD AND REAR GLASS...........................................620
	CAB COMPONENTS..................................................................621
		CAB COMPONENTS..............................................................621
			WINDSHIELD WIPER........................................................621
			WINDSHIELD WASHER.......................................................622
	OPERATOR COMPORT................................................................623
		OPERATOR SEAT...............................................................623
			ADJUSTMENT..............................................................623
		HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS INSTRUMENT .................624
			HEATER COMPONENTS.......................................................625
				FILTER..............................................................627
	OPERATOR CONTROLS AND EQUIPMENT.................................................629
		STEERING WHEEL AND CONTROLS.................................................630
			STEERING COLUMN.........................................................630
		HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS.............................633
		INSTRUMENT PANEL............................................................634
		CENTER CONSOLE..............................................................635
			HOIST CONTROL LEVER.....................................................636
	INSTRUMENT PANEL AND INDICATOR LIGHTS...........................................639
		INSTRUMENT PANEL AND INDICATOR LIGHTS.......................................639
			CONTROL SYMBOLS.........................................................639
		INSTRUMENT PANEL............................................................640
			PANEL GAUGES, INDICATORS, AND CONTROLS..................................641
			INDICATOR LIGHT SYMBOLS.................................................646
LUBRICATION AND SERVICE.............................................................651
	LUBRICATION AND SERVICE.........................................................653
		LUBRICATION SPECIFICATIONS CHARTS...........................................653
			SERVICE CAPACITIES......................................................653
			HYDRAULIC TANK SERVICE AND FILING INSTRUCTIONS..........................653
			RADIATOR FILING PROCEDURE...............................................654
			ANTI-FREEZE SPECIFICATIONS..............................................654
			LUBRICATION CHART - OIL GREASE SPECIFICATIONS...........................655
		10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS..........................656
		50 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................658
		100 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................659
		250 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................660
		500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................662
		1000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................663
		2500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................664
		5000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................665
	AUTOMATIC LUBRICATION SYSTEM....................................................667
		GENERAL DESCRIPTION.........................................................667
		SYSTEM COMPONENTS...........................................................669
		SYSTEM OPERATION............................................................670
			INJECTOR OPERATION......................................................672
		GENERAL INSTRUCTIONS........................................................673
		SYSTEM CHECKOUT.............................................................675
			PUMP REBUILD............................................................676
			SYSTEM TROUBLESHOOTING CHART............................................679
		PREVENTATIVE MAINTENANCE PROCEDURES.........................................682
	MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................683
ALPHABETICAL INDEX..................................................................687
SYSTEM SCHEMATICS...................................................................691
	HYDRAULIC HOIST/STEERING SCHEMATIC..............................................693
	HYDRAULIC BRAKE SCHEMATIC (STATEX III; LAPS)....................................694
	STATEX III FL-275 PANEL.........................................................695
	STATEX III POWER & EXCITATION SCHEMATIC.........................................725
	STATEX III ELECTRICAL CONTROL CABINET COMPONENT LOCATION........................728

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