KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30392 & A30393 )
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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30392 & A30393 )
- This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must understand the content in this manual before maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before repairing the truck.
- This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to right, left, front, or rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lbs).
- All torque specifications have ±10% tolerance unless otherwise specified. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW) rating.
- The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the total maximum GVW. GVW is the total truck weight. This is equal to the empty vehicle weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty truck. This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating. The result is the allowable payload
TABLE OF CONTENTS:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30392 & A30393 )
MAIN MENU........................................................................................................ 0 COVER............................................................................................................ 1 FOREWORD......................................................................................................... 5 TABLE OF CONTENTS................................................................................................ 7 SECTION A - GENERAL INFORMATION - INDEX.......................................................................... 9 SECTION A2 - MAJOR COMPONENT DESCRIPTION..................................................................... 11 SECTION A3 - GENERAL SAFETY AND OPERATION - INDEX............................................................ 15 GENERAL SAFETY........................................................................................... 17 PERSONAL SAFETY...................................................................................... 17 Safety Rules..................................................................................... 17 Truck Safety Features............................................................................ 17 Clothing And Personal Items...................................................................... 17 Unauthorized Modification........................................................................ 17 Leaving The Operator’s Seat...................................................................... 17 Mounting And Dismounting......................................................................... 18 Fire Extinguishers And First Aid Kits............................................................ 18 Precautions For High Temperature Fluids.......................................................... 18 Asbestos Dust Hazard Prevention.................................................................. 18 Fire Prevention For Fuel And Oil................................................................. 19 ROPS Precautions................................................................................. 19 Preventing Injury From Work Equipment............................................................ 19 Precautions For Optional Attachments............................................................. 19 Precautions When Starting The Machine............................................................ 19 PRECAUTIONS FOR TRUCK OPERATION...................................................................... 20 Safety Is Thinking Ahead......................................................................... 20 Safety At The Work Site.......................................................................... 20 Fire Prevention.................................................................................. 20 Preparing For Operation.......................................................................... 20 Ventilation For Enclosed Areas................................................................... 20 Mirrors, Windows, And Lights..................................................................... 21 In The Operator’s Cab - Before Starting The Engine............................................... 21 OPERATING THE MACHINE................................................................................ 21 Starting The Engine.............................................................................. 21 Truck Operation - General........................................................................ 21 Traveling In The Truck........................................................................... 22 Precautions When Traveling In Reverse............................................................ 22 Traveling On Slopes.............................................................................. 23 Ensuring Good Visibility......................................................................... 23 Operating On Snow................................................................................ 23 Avoid Damage To The Dump Body.................................................................... 23 Driving Near High-Voltage Cables................................................................. 23 When Loading The Truck........................................................................... 24 When Dumping..................................................................................... 24 Working On Loose Ground.......................................................................... 24 Parking The Machine.............................................................................. 24 TOWING............................................................................................... 24 WORKING NEAR BATTERIES............................................................................... 25 Battery Hazard Prevention........................................................................ 25 Jump-Starting With Booster Cables................................................................ 25 MAINTENANCE PRECAUTIONS.............................................................................. 25 BEFORE PERFORMING MAINTENANCE.................................................................... 25 Stopping The Engine Before Service........................................................... 25 Warning Tag.................................................................................. 26 Proper Tools................................................................................. 26 Securing The Dump Body....................................................................... 26 DURING MAINTENANCE............................................................................... 27 Personnel.................................................................................... 27 Attachments.................................................................................. 27 Working Under The Machine.................................................................... 27 Keeping The Machine Clean.................................................................... 27 Adding Fuel Or Oil........................................................................... 27 Radiator Coolant Level....................................................................... 27 Use Of Lighting.............................................................................. 28 Precautions With The Battery................................................................. 28 Handling High-Pressure Hoses................................................................. 28 Precautions With High-Pressure Oil........................................................... 28 Maintenance Near High Temperatures And High Pressures........................................ 28 Rotating Fan And Belts....................................................................... 28 Waste Materials.............................................................................. 28 TIRES............................................................................................ 29 Handling Tires............................................................................... 29 Tire Maintenance............................................................................. 29 Storing Tires After Removal.................................................................. 30 ADDITIONAL JOB SITE RULES................................................................................ 31 WHEN REPAIRS ARE NECESSARY............................................................................... 32 OPERATING INSTRUCTIONS................................................................................... 33 PREPARING FOR OPERATION.............................................................................. 33 SAFETY IS THINKING AHEAD............................................................................. 33 WALK-AROUND INSPECTION............................................................................... 33 ENGINE START-UP...................................................................................... 37 AFTER THE ENGINE HAS STARTED......................................................................... 38 MACHINE OPERATION SAFETY PRECAUTIONS................................................................. 39 LOADING.............................................................................................. 39 HAULING.............................................................................................. 40 PASSING.............................................................................................. 40 DUMPING.............................................................................................. 41 To Raise The Dump Body:.......................................................................... 41 To Lower The Dump Body: (When dumping over a berm or into a crusher):............................ 42 To Lower The Dump Body (When dumping on flat ground):............................................ 42 TOWING............................................................................................... 43 SAFE PARKING PROCEDURES.............................................................................. 43 ENGINE SHUTDOWN PROCEDURE............................................................................ 44 DELAYED ENGINE SHUTDOWN PROCEDURE.................................................................... 44 SUDDEN LOSS OF POWER................................................................................. 45 EMERGENCY STEERING SYSTEM............................................................................ 45 Operation........................................................................................ 45 Testing.......................................................................................... 46 TROLLEY OPERATING INSTRUCTIONS....................................................................... 46 AFTER THE ENGINE HAS STARTED..................................................................... 46 OPERATING IN DIESEL MODE......................................................................... 47 OPERATING IN TROLLEY LINE MODE................................................................... 47 GETTING ON LINE.................................................................................. 48 Operating On Trolley......................................................................... 50 GETTING OFF LINE................................................................................. 51 LINE STATUS SIGNALS.............................................................................. 51 LINE STATUS SIGNAL MARKINGS...................................................................... 52 TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION................................................. 52 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK..................................... 53 OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS........................................... 53 TRUCK FAILURE WHILE ON TROLLEY................................................................... 53 SECTION A4 -WARNINGS AND CAUTIONS............................................................................ 55 SECTION A5 -STANDARD TORQUE CHARTS AND CONVERSION TABLES..................................................... 63 SECTION A7 - STORAGE AND IDLE MACHINE PREPARATION - INDEX.................................................... 69 STORAGE AND IDLE MACHINE PREPARATION..................................................................... 71 SHORT TERM IDLE PERIODS.............................................................................. 71 PREPARATION FOR STORAGE.............................................................................. 72 REMOVAL FROM STORAGE................................................................................. 73 RECONDITIONING AN IDLE VEHICLE....................................................................... 74 ENGINE OPERATION..................................................................................... 77 After The Engine Has Started..................................................................... 77 ENGINE STORAGE....................................................................................... 78 Temporary Storage (30 Days Or Less).............................................................. 78 Extended Storage (More Than 30 Days)............................................................. 79 RESTORING AN ENGINE AFTER EXTENDED STORAGE........................................................... 80 ELECTRIC DRIVE TRUCKS................................................................................ 81 Storing A Truck That Is Operational.............................................................. 81 Storing A Truck That Is Not Operational.......................................................... 82 Storing A Major Component........................................................................ 83 Periodic Inspections............................................................................. 83 Placing Equipment Into Service After Storage..................................................... 83 SECTION B - STRUCTURES - INDEX................................................................................... 85 SECTION B2 - STRUCTURAL COMPONENTS - INDEX................................................................... 87 STRUCTURAL COMPONENTS.................................................................................... 89 LADDERS.............................................................................................. 89 Removal.......................................................................................... 89 Installation..................................................................................... 89 GRILLE AND HOOD...................................................................................... 90 Removal.......................................................................................... 90 Installation..................................................................................... 90 RIGHT-HAND DECK...................................................................................... 90 Removal.......................................................................................... 90 Installation..................................................................................... 92 CENTER DECK.......................................................................................... 92 LEFT-HAND DECK....................................................................................... 93 Removal.......................................................................................... 93 Installation..................................................................................... 93 SECTION B3 - DUMP BODY - INDEX............................................................................... 95 DUMP BODY................................................................................................ 97 DUMP BODY............................................................................................ 97 Removal.......................................................................................... 97 Installation..................................................................................... 98 BODY SLING........................................................................................... 98 BODY PADS............................................................................................ 99 Adjustment....................................................................................... 99 BODY GUIDE........................................................................................... 100 BODY POSITION INDICATOR.............................................................................. 100 HOIST LIMIT SWITCH................................................................................... 100 ROCK EJECTORS........................................................................................ 100 Inspection....................................................................................... 100 SECTION B4 - FUEL TANK -INDEX................................................................................ 101 FUEL TANK................................................................................................ 103 Removal.............................................................................................. 103 Repair............................................................................................... 103 Cleaning............................................................................................. 103 Installation......................................................................................... 104 FUEL GAUGE SENDER........................................................................................ 105 Removal.............................................................................................. 105 Installation......................................................................................... 105 LOW FUEL SENDER.......................................................................................... 106 Removal.............................................................................................. 106 Installation......................................................................................... 106 FUEL RECEIVER............................................................................................ 107 TANK BREATHER VALVE...................................................................................... 108 Removal.............................................................................................. 108 Installation......................................................................................... 108 Disassembly.......................................................................................... 108 Assembly............................................................................................. 108 SECTION C - ENGINE - INDEX....................................................................................... 109 SECTION C2 - POWER MODULE - INDEX............................................................................ 111 POWER MODULE............................................................................................. 113 GENERAL INFORMATION.................................................................................. 113 POWER MODULE SERVICE................................................................................. 114 Removal.......................................................................................... 114 Installation..................................................................................... 118 SECTION C3 - COOLING SYSTEM - INDEX.......................................................................... 121 COOLING SYSTEM........................................................................................... 123 RADIATOR............................................................................................. 123 Removal.......................................................................................... 123 Service.......................................................................................... 124 Installation..................................................................................... 124 RADIATOR FILL PROCEDURE.......................................................................... 125 RADIATOR REPAIR.................................................................................. 125 Internal Inspection.......................................................................... 125 External Cleaning............................................................................ 126 Disassembly.................................................................................. 126 Cleaning and Inspection...................................................................... 127 Assembly..................................................................................... 127 Additional Service Information............................................................... 129 PRESSURE TESTING................................................................................. 129 COOLANT SYSTEM TROUBLESHOOTING................................................................... 129 SECTION C4 - POWER TRAIN - INDEX............................................................................. 131 POWER TRAIN.............................................................................................. 133 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE........................................................ 133 General Information.............................................................................. 133 Removal.......................................................................................... 133 ALTERNATOR INSTALLATION.............................................................................. 135 Engine/Alternator Mating......................................................................... 135 Alternator Measurement........................................................................... 135 Engine End Play Measurement...................................................................... 136 Determining Shim Requirements.................................................................... 137 Installing Alternator On Engine.................................................................. 138 ENGINE............................................................................................... 139 Removal.......................................................................................... 139 Installation..................................................................................... 139 SECTION C5 - AIR CLEANERS - INDEX............................................................................ 141 AIR CLEANERS............................................................................................. 143 Service Checks....................................................................................... 143 Filter Element Replacement........................................................................... 144 Main Filter Element Cleaning......................................................................... 146 Precleaner Section................................................................................... 147 Cleaning Precleaner Tubes............................................................................ 147 Air Intake Troubleshooting........................................................................... 148 SECTION C7 - FAN DRIVE CLUTCH - INDEX........................................................................ 149 FAN DRIVE CLUTCH......................................................................................... 151 GENERAL DESCRIPTION.................................................................................. 151 COMPONENTS........................................................................................... 151 Input............................................................................................ 151 Output........................................................................................... 151 Stationary Components............................................................................ 152 OPERATION MODES...................................................................................... 153 Fully Engaged.................................................................................... 153 Modulated Variable Speed......................................................................... 153 Fully Released................................................................................... 154 Remember:........................................................................................ 154 Lubricating and Cooling Oil...................................................................... 155 MAINTENANCE.......................................................................................... 156 Maintenance Checks To Be Made.................................................................... 156 TROUBLESHOOTING...................................................................................... 157 Basic Preliminary Checks......................................................................... 157 FIELD CHECK DIAGNOSIS................................................................................ 158 Preliminary Checks With Engine Off............................................................... 158 Check Clutch Release............................................................................. 158 Check Clutch Lock-up............................................................................. 159 Overheating Complaint............................................................................ 160 Thermal Sensor and Solenoid Valve................................................................ 160 On Truck Test.................................................................................... 160 Off Truck Test................................................................................... 161 Test Conditions and Requirements:................................................................ 161 Test:............................................................................................ 161 TROUBLESHOOTING CHART.................................................................................... 162 FAN CLUTCH DISASSEMBLY INSTRUCTIONS...................................................................... 165 REASSEMBLY OF THE FAN CLUTCH............................................................................. 172 INSPECTION OF PARTS...................................................................................... 183 REBUILD TOOLS............................................................................................ 186 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX..................................................... 189 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX............................................................ 191 24VDC ELECTRIC SUPPLY SYSTEM............................................................................. 193 ELECTRICAL SYSTEM DESCRIPTION........................................................................ 193 BATTERIES............................................................................................ 193 Maintenance and Service.......................................................................... 193 Troubleshooting.................................................................................. 193 BATTERY CHARGING ALTERNATOR.......................................................................... 195 24VDC ELECTRIC START SYSTEM.......................................................................... 195 CRANKING MOTORS.................................................................................. 195 Removal...................................................................................... 195 Installation................................................................................. 196 CRANKING MOTOR TROUBLESHOOTING................................................................... 196 Preliminary Inspection....................................................................... 197 No-Load Test................................................................................. 197 Interpreting Results of Tests................................................................ 197 Disassembly.................................................................................. 198 Cleaning and Inspection...................................................................... 198 Armature Servicing........................................................................... 198 Field Coil Checks............................................................................ 201 Field Coil Removal........................................................................... 201 Solenoid Checks.............................................................................. 201 Test......................................................................................... 201 Assembly..................................................................................... 202 Pinion Clearance............................................................................. 203 MAGNETIC SWITCH.................................................................................. 204 Coil Test.................................................................................... 204 Electric Start System Wiring Diagrams........................................................ 204 ENGINE PRELUB SYSTEM................................................................................. 204 OPERATION........................................................................................ 204 Pressure Switch.............................................................................. 205 Suction Line................................................................................. 205 Outlet Line.................................................................................. 205 Check Valve.................................................................................. 205 Solenoid Timer............................................................................... 205 TROUBLESHOOTING PRELUB STARTER CIRCUIT................................................................... 207 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX........................................................ 211 24VDC ELECTRICAL SYSTEM COMPONENTS....................................................................... 213 PASSENGER SEAT BASE COMPARTMENT...................................................................... 213 COMPONENTS........................................................................................... 213 Taillight Resistor Diode Assemblies.............................................................. 213 Inclinometer..................................................................................... 213 Brake Warning Buzzer (BWB)....................................................................... 213 Lubrication System Timer......................................................................... 213 Five Minute Idle Timer Components................................................................ 213 Five Minute Idle Timer........................................................................... 215 Five Minute Idle Relay........................................................................... 215 Five Minute Idle Contactor....................................................................... 215 Five Minute Idle Circuit Test.................................................................... 215 Data Store Switch................................................................................ 215 Komatsu Engine Quantum Connector (Not Used)...................................................... 215 Komatsu Engine Cense Connector................................................................... 215 STATEX III Propulsion System Diagnostic Connector................................................ 215 Spare Connector Location......................................................................... 215 Alarm Indicating Device (AID) System............................................................. 216 Diode Matrix (Without Sound)..................................................................... 216 Diode Matrix (With Sound)........................................................................ 217 Hot Switch Inverter.............................................................................. 217 Hot Switch Inverter Card (Slot 4) (Not Used)..................................................... 217 Temperature...................................................................................... 217 Oil Level........................................................................................ 217 Temperature and Latch............................................................................ 217 Coolant Level/Flasher............................................................................ 218 Lamp Test........................................................................................ 218 BATTERY EQUALIZER BOX................................................................................ 218 Troubleshooting.................................................................................. 218 BODY-UP SWITCH....................................................................................... 219 Adjustment....................................................................................... 219 Service.......................................................................................... 219 HOIST LIMIT SWITCH................................................................................... 220 Adjustment....................................................................................... 220 Service.......................................................................................... 220 24-VOLT RELAY AND DIODE BOARDS....................................................................... 220 RELAY BOARDS......................................................................................... 221 Description...................................................................................... 221 SERVICE.............................................................................................. 221 To Replace A Relay:.............................................................................. 221 To Replace A Circuit Breaker:.................................................................... 221 To Replace A Circuit Panel Card.................................................................. 222 Relay Board Components........................................................................... 222 Installing Additional Circuits................................................................... 223 DIODE BOARD 1.................................................................................... 224 Diode Testing.................................................................................... 224 CIRCUIT BREAKERS..................................................................................... 226 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX............................................................ 227 BATTERY CHARGING SYSTEM.................................................................................. 231 BATTERY CHARGING SYSTEM.............................................................................. 231 ELECTRICAL SYSTEM DESCRIPTION.................................................................... 231 CHARGE VOLT AND AMP VALUES....................................................................... 231 BATTERY.......................................................................................... 231 Maintenance and Service...................................................................... 231 Troubleshooting.............................................................................. 232 Undercharging................................................................................ 232 Overcharging................................................................................. 232 Corrosion.................................................................................... 232 Acid Levels.................................................................................. 232 Non-Use or Storage........................................................................... 232 Freezing..................................................................................... 233 BATTERY CHARGING ALTERNATOR.......................................................................... 234 GENERAL INFORMATION.............................................................................. 234 General Description.......................................................................... 234 Terminal Identification and Location......................................................... 235 Battery Positive (B+)........................................................................ 235 Battery Negative (B-)........................................................................ 235 DC Output (D+)............................................................................... 235 AC Output (R)................................................................................ 235 Regulator Harness Plug Identification........................................................ 235 Alternator Specifications.................................................................... 235 Performance Curve............................................................................ 235 Battery/Alternator Terminology............................................................... 236 WIRING DIAGRAM................................................................................... 238 DIMENSIONS AND TORQUE VALUES..................................................................... 239 PERIODIC MAINTENANCE............................................................................. 240 TESTING.............................................................................................. 240 GENERAL INFORMATION.............................................................................. 240 Troubleshooting Alternator (On-Truck)........................................................ 240 Equipment Required........................................................................... 240 Preliminary Checks........................................................................... 240 Test Set-up.................................................................................. 242 Test Procedure............................................................................... 243 REGULATOR TESTING................................................................................ 244 Regulator Bypass Test (No Output)............................................................ 244 Regulator Bypass Test (Amp Rating)........................................................... 245 BENCH TESTING.................................................................................... 246 Equipment.................................................................................... 246 Identification Record........................................................................ 246 Advanced Troubleshooting..................................................................... 246 Bench Test 1: No-Load Test................................................................... 246 Bench Test 2: Full Load Test................................................................. 247 Bench Test 3: Regulator Bypass Test.......................................................... 247 STATIC TESTING................................................................................... 248 Equipment.................................................................................... 248 Identification Record........................................................................ 248 Regulator Tester............................................................................. 248 Check For Shorted Power Transistor........................................................... 248 Circuit Tests................................................................................ 249 FIELD COIL TESTS................................................................................. 250 Field Coil Test 1: Check for Open or Shorted Field Coil...................................... 250 Field Coil Test 2: Check For Grounded Field Coil............................................. 250 STATOR TESTS..................................................................................... 251 Stator Test 1: Check For Stator-To-Stator Continuity......................................... 251 Stator Test 2: Check For Grounded Stators.................................................... 252 THERMAL SWITCH TEST.............................................................................. 252 Initial Test................................................................................. 252 Verifying a Faulty Thermal Switch............................................................ 253 TROUBLESHOOTING TIPS............................................................................. 254 ALTERNATOR........................................................................................... 258 ALTERNATOR REPAIR................................................................................ 258 Removal...................................................................................... 258 Installation................................................................................. 260 Special Tools and Lubricants................................................................. 260 Epoxy Adhesive............................................................................... 261 Liquid Threadlockers......................................................................... 261 Elastoplastic Silicone Resin................................................................. 261 ALTERNATOR EXPLODED VIEW......................................................................... 264 ALTERNATOR DISASSEMBLY........................................................................... 266 Regulator Removal............................................................................ 266 Fan Removal.................................................................................. 267 Pulley Removal............................................................................... 268 Anti-Drive End Housing Removal............................................................... 268 Anti-Drive End Rotor Removal................................................................. 270 Drive End Housing Removal.................................................................... 272 Drive End Rotor Removal...................................................................... 278 Field Coil Removal........................................................................... 279 Drive End and/or Anti-Drive End Stator Removal............................................... 281 CLEANING AND INSPECTION.......................................................................... 283 ALTERNATOR ASSEMBLY.............................................................................. 283 Anti-Drive End Stator Installation........................................................... 283 Drive End Stator Installation................................................................ 285 Field Coil Installation...................................................................... 288 Drive End Bearing Installation............................................................... 290 Drive End Rotor Installation................................................................. 292 Rotor and Rotor Shaft Installation........................................................... 292 Drive End Housing Installation............................................................... 293 Anti-Drive End Rotor Installation............................................................ 297 Anti-Drive End Housing Installation.......................................................... 298 Regulator Installation....................................................................... 301 THERMAL SWITCH................................................................................... 302 Removal...................................................................................... 302 Installation................................................................................. 304 SUPPORT STAND.................................................................................... 304 SECTION D35 - PAYLOAD METER III - INDEX...................................................................... 305 OPERATION SECTION........................................................................................ 311 Introduction......................................................................................... 311 Data Summary..................................................................................... 311 Data Gathering................................................................................... 311 COMPONENT DESCRIPTION................................................................................ 312 System Diagram................................................................................... 312 Suspension Pressure Sensors...................................................................... 312 Inclinometer..................................................................................... 312 Operator Display................................................................................. 312 Operator Switch.................................................................................. 313 Speed Input...................................................................................... 313 Body-Up Switch................................................................................... 313 Brake Lock Switch................................................................................ 313 Payload Meter.................................................................................... 313 Communications Ports............................................................................. 313 Key Switch Input................................................................................. 314 Payload Meter Power.............................................................................. 314 Load Lights...................................................................................... 314 Wiring and Termination........................................................................... 315 TCI Outputs...................................................................................... 315 OPERATOR’S DISPLAY AND SWITCH........................................................................ 316 Reading the Speedometer.......................................................................... 316 Reading the Load Display......................................................................... 316 Using the Operator ID............................................................................ 316 Using the Load and Ton Counter................................................................... 316 Total Ton Counter................................................................................ 316 Total Load Counter............................................................................... 317 Clearing the Counters............................................................................ 317 Viewing Live Sensor Data......................................................................... 317 Other Display Messages........................................................................... 317 PAYLOAD OPERATION AND CALCULATION.................................................................... 318 Description of Haul Cycle States................................................................. 318 Haul Cycle Description........................................................................... 318 Load Calculation................................................................................. 319 Carry Back....................................................................................... 319 Measurement Accuracy............................................................................. 319 SOURCES FOR PAYLOAD ERROR............................................................................ 319 Payload Error.................................................................................... 319 Loading Conditions............................................................................... 320 Pressure Sensors................................................................................. 320 Swingloads....................................................................................... 320 Speed and Distance............................................................................... 320 HAUL CYCLE DATA...................................................................................... 320 Haul Cycle Data.................................................................................. 321 Haul Cycle Warning Flags......................................................................... 322 Frame Torque Data................................................................................ 323 Sprung Weight Data............................................................................... 323 Maximum Speed Data............................................................................... 323 Alarm Records.................................................................................... 323 Fault Code Data.................................................................................. 324 PC SOFTWARE OVERVIEW................................................................................. 325 PC Overview...................................................................................... 325 System Configuration............................................................................. 325 Installing the PLMIII Software................................................................... 325 DOWNLOADING DATA..................................................................................... 326 PLM III SYSTEM CONFIGURATION......................................................................... 327 Starting Communications.......................................................................... 327 Displayed Payload Units.......................................................................... 327 Time Units....................................................................................... 327 Connection Menu.................................................................................. 327 Connecting to the Payload Meter.................................................................. 328 Configure the Payload Meter...................................................................... 328 Setting the Date and Time........................................................................ 328 Setting the Truck Type........................................................................... 329 Setting the Gauge Display Units.................................................................. 329 Setting the Frame Serial Number.................................................................. 329 Setting the Truck Number......................................................................... 329 Setting the Komatsu Distributor.................................................................. 329 Setting the Komatsu Customer..................................................................... 329 Clean Truck Tare................................................................................. 330 Inclinometer Calibration......................................................................... 330 DATA ANALYSIS........................................................................................ 331 Creating a Query................................................................................. 331 Sorting on Truck Unit Number..................................................................... 331 Sorting on Truck Type............................................................................ 331 Sorting on Date Range............................................................................ 332 Sorting on Time Range............................................................................ 332 Payload Detail Screen............................................................................ 333 Creating Reports................................................................................. 333 Summary - One Page Report........................................................................ 334 Detailed - Multi-Page Report..................................................................... 334 Creating Graphs.................................................................................. 335 Exporting Data................................................................................... 335 CSV Export....................................................................................... 335 Compressed....................................................................................... 337 Importing Data................................................................................... 337 Deleting Haul Cycle Records...................................................................... 337 Viewing Alarms................................................................................... 338 Deleting Alarm Records........................................................................... 338 TROUBLESHOOTING SECTION.................................................................................. 339 TROUBLESHOOTING...................................................................................... 339 Viewing Active Alarms............................................................................ 339 Real-Time Data Display........................................................................... 339 Testing the Payload Lights....................................................................... 340 Creating Log Files of Inputs..................................................................... 340 Daily Inspections................................................................................ 340 Periodic Maintenance............................................................................. 340 Abnormal Displays at Power-Up.................................................................... 341 No Payload Display When Key Switch is Turned On.................................................. 342 No Display on Speedometer........................................................................ 343 No Display on Operator Display................................................................... 343 No Communications With PC........................................................................ 344 Load Lights Don’t Light During Loading........................................................... 345 Load Lights Remain On............................................................................ 346 Load Lights Remain On During Dumping............................................................. 346 Display Doesn't Clear When The Load Is Dumped.................................................... 346 Calibration Problems............................................................................. 347 Alarm 1 - Left-Front Pressure High............................................................... 348 Alarm 2 - Left-Front Pressure Low................................................................ 348 Troubleshoot Wiring to Left-Front Suspension..................................................... 348 Alarm 3 - Right-Front Pressure High.............................................................. 349 Alarm 4 - Right-Front Pressure Low............................................................... 349 Troubleshoot Wiring to Right-Front Suspension.................................................... 349 Alarm 5 - Left-Rear Pressure High................................................................ 350 Alarm 6 - Left-Rear Pressure Low................................................................. 350 Troubleshoot Wiring to Left-Rear Suspension...................................................... 350 Alarm 7 - Right-Rear Pressure High............................................................... 351 Alarm 8 - Right-Rear Pressure Low................................................................ 351 Troubleshoot Wiring to Right-Rear Suspension..................................................... 351 Alarm 9 - Inclinometer High...................................................................... 352 Alarm 10 - Inclinometer Low...................................................................... 352 Troubleshoot Inclinometer Wiring................................................................. 352 Alarm 13 - Body-Up Input Failure................................................................. 353 Alarm 16 - Memory Write Failure.................................................................. 354 Alarm 17 - Memory Read Failure................................................................... 354 Alarm 18......................................................................................... 355 Alarm 19......................................................................................... 355 Alarm 22......................................................................................... 355 Operator Switch Doesn't Work..................................................................... 356 Alarm 26 - User Switch Fault - SELECT............................................................ 356 Alarm 27 - User Switch Fault - SET............................................................... 356 Connector Map.................................................................................... 357 Connectors....................................................................................... 358 PLMIII CHECKOUT PROCEDURE................................................................................ 359 General Description.................................................................................. 359 Tools Required....................................................................................... 359 Checkout Procedure................................................................................... 359 PLMIII CHECKOUT PROCEDURE CONFIRMATION............................................................... 363 Flashburn Programming............................................................................ 363 Confirmation Checklist........................................................................... 365 SECTION E - ELECTRICAL PROPULSION - INDEX........................................................................ 367 SECTION E2 - ELECTRICAL PROPULSION COMPONENTS - INDEX........................................................ 369 ELECTRICAL PROPULSION COMPONENTS......................................................................... 373 GENERAL SYSTEM DESCRIPTION........................................................................... 373 CONTROL SYSTEM....................................................................................... 373 System Operation................................................................................. 374 FL275 Panel...................................................................................... 375 CARD REPLACEMENT..................................................................................... 376 Removal.......................................................................................... 376 Installation..................................................................................... 376 Card Repair...................................................................................... 376 Panel Wiring..................................................................................... 376 COMPUTER DESCRIPTION................................................................................. 377 Microprocessor................................................................................... 377 Download Capability.............................................................................. 377 SOFTWARE............................................................................................. 377 Base Monitor Program............................................................................. 377 Runtime Monitor Program - OBJ Running Code....................................................... 377 Configuration Software - CFG..................................................................... 378 PTU - Portable Test Unit Code.................................................................... 378 System Regulation................................................................................ 378 Propulsion....................................................................................... 379 Retarding........................................................................................ 379 TWO-DIGIT DISPLAY PANEL.............................................................................. 380 The Coded Number................................................................................. 380 Events........................................................................................... 380 Frames........................................................................................... 381 Windows.......................................................................................... 381 System Categories................................................................................ 381 Limits On Resetting Faults....................................................................... 381 NA Faults........................................................................................ 382 Event Sequence................................................................................... 382 Resetting Events................................................................................. 382 Event Descriptions............................................................................... 382 Subcode Descriptions............................................................................. 382 2-DIGIT DISPLAY PANEL SUBCODES....................................................................... 390 PORTABLE TEST UNIT (PTU)................................................................................. 393 DESCRIPTION.......................................................................................... 393 Operational Hints................................................................................ 393 SOFTWARE INSTALLATION PREPARATION.................................................................... 394 HARD DISK SPACE REQUIREMENTS......................................................................... 394 SOFTWARE INSTALLATION ON PTU......................................................................... 394 PTU/Truck Communication Problems................................................................. 395 THE MAIN MENU........................................................................................ 396 Quit Menu........................................................................................ 396 PTU Talk To Truck................................................................................ 396 View PTU Saved Files............................................................................. 396 List Stat Data Files............................................................................. 396 Truck Setup (CFG)................................................................................ 396 Select Truck Setup............................................................................... 396 Update CFG Version............................................................................... 396 Change PTU Password.............................................................................. 396 CONFIGURATION (CFG) FILE CONVERSION.................................................................. 398 Conversion Procedure............................................................................. 398 Convert Old CFG files for New software........................................................... 399 STATEX CONFIGURATION FILES........................................................................... 402 0) Source Directory: . . ........................................................................ 402 1) Select A Truck Configuration . . ............................................................. 403 2) View Truck Configuration: Data Curves . . .................................................... 404 3) Change/View Serial and Model Numbers . . ..................................................... 405 4) View Options . . ............................................................................. 405 5) Change/View Truck Specifics . . .............................................................. 407 6) Change/View Overspeeds . . ................................................................... 409 7) Save a Truck Configuration, filename: . . .................................................... 410 8) Save Directory: . . .......................................................................... 411 CHANGE PTU PASSWORD.................................................................................. 412 PROGRAMMING THE TRUCK................................................................................ 413 Connect PTU to the Truck......................................................................... 413 Select Configuration File........................................................................ 413 Activate The PTU Mode............................................................................ 413 Check Object Code Version........................................................................ 414 Download Configuration Files..................................................................... 415 Date And Time.................................................................................... 416 Event Data....................................................................................... 417 Statistical Data................................................................................. 419 View Counters.................................................................................... 419 View Profiles.................................................................................... 419 Upload Statistical Data To A File................................................................ 419 Statistical Data Codes - Counters................................................................ 420 STATISTICAL DATA CODES - COUNTERS.................................................................... 421 STATISTICAL DATA CODES - PROFILES.................................................................... 426 TRUCK SPECIFIC INFORMATION........................................................................... 430 Temporary Truck Settings......................................................................... 431 MISCELLANEOUS FEATURES............................................................................... 432 Saving Data...................................................................................... 432 PTU Abbreviations................................................................................ 433 Other Menu Selections............................................................................ 433 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS........................................................... 434 ALTERNATOR........................................................................................... 434 ELECTRIC WHEEL MOTORS................................................................................ 434 RETARDING GRIDS...................................................................................... 434 ELECTRONIC ACCELERATOR AND RETARD PEDALS............................................................. 434 Removal.......................................................................................... 434 Installation..................................................................................... 434 Disassembly...................................................................................... 435 Reassembly....................................................................................... 435 COOLING BLOWER WARNING SYSTEM........................................................................ 435 Operation........................................................................................ 435 Test............................................................................................. 435 Removal.......................................................................................... 436 Installation..................................................................................... 436 ELECTRICAL CONTROL CABINET............................................................................... 437 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS................................................... 442 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III....................................................... 443 SECTION E3 - STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE - INDEX......................................... 445 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.......................................................... 449 GENERAL INFORMATION.................................................................................. 449 COMMUNICATIONS PORT CHECK............................................................................ 450 PTU Hookup....................................................................................... 450 4.0 SEQUENCE TESTS - (ENGINE NOT ON)................................................................. 451 Preparation and Setup............................................................................ 451 CONTROL SYSTEM SELF-TEST......................................................................... 452 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT......................................................... 452 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT........................................................... 453 PTU Setup.................................................................................... 453 4.3 REVERSER AND PROPULSION CONTACTORS CHECK..................................................... 454 4.4 NOT USED..................................................................................... 455 4.5 RETARD CONTACTORS OPERATION CHECK............................................................ 455 4.6 GROUND FAULT SENSING CHECK................................................................... 455 4.7 GROUND FAULT IN RETARD OPERATION CHECK....................................................... 456 4.8 OVERRIDE OPERATION CHECK..................................................................... 456 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK............................................................ 457 4.10 OVERSPEED RETARD OPERATION CHECK............................................................ 457 4.11 HOIST INTERLOCK OPERATION CHECK............................................................. 458 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.................................................... 458 Return to Main Menu.......................................................................... 458 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL............................................. 459 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU................................................ 459 5.2 DIGITAL INPUT CHECKS......................................................................... 460 5.3 DIGITAL OUTPUT CHECKS........................................................................ 461 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL..................................................... 465 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU..................................................... 465 6.2 ANALOG INPUT CHECKS.......................................................................... 466 6.3 FREQUENCY INPUT CHECKS....................................................................... 470 Return to Main Menu.......................................................................... 471 7.0 SPEED EVENT CHECKS............................................................................... 471 Preparation and Setup............................................................................ 471 Setup PTU........................................................................................ 471 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK...................................... 472 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK........................... 472 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK.......................... 472 7.4 OTHER SPEED EVENTS CHECKS.................................................................... 472 Return to Main Menu.......................................................................... 472 8.0 RETARD SPEED CONTROL SYSTEM CHECK................................................................ 473 Preparation and Setup............................................................................ 473 Setup PTU........................................................................................ 473 8.1 OVERSPEED PICKUP AND DROPOUT CHECK........................................................... 473 8.2 RETARD POT MAXIMUM SETTING CHECK............................................................. 473 8.3 RETARD POT MINIMUM SETTING CHECK............................................................. 473 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL........................................... 474 Return to Main Menu.......................................................................... 474 9.0 LOAD TEST USING TRUCK RETARD GRIDS............................................................... 474 Setup and Preparation............................................................................ 474 PTU Setup........................................................................................ 474 9.1 LOAD TEST.................................................................................... 475 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING.......................................................... 475 Setup PTU........................................................................................ 475 10.1 RETARD CHECK................................................................................ 476 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT..................................................... 477 11.1 BRAKE SYSTEM INTERLOCKS CHECK............................................................... 477 Preparation.................................................................................. 477 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT...................................................... 477 11.3 SYNC TRANSFORMER CHECKOUT................................................................... 478 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT.................................................. 478 11.5 BATTERY BOOST ADJUSTMENT.................................................................... 478 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST................................................. 478 11.7 MOTOR ROTATION TEST......................................................................... 479 11.8 GROUND FAULT CHECKS......................................................................... 479 12.0 MISCELLANEOUS CHARTS............................................................................ 480 12.1 WHEEL MOTOR GEAR RATIOS..................................................................... 480 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS.............................................................. 481 12.3 ENGINE OPTIONS.............................................................................. 482 SECTION G - DRIVE AXLE, SPINDLE AND WHEEL - INDEX................................................................ 483 SECTION G2 - TIRES AND RIMS - INDEX.......................................................................... 485 TIRES AND RIMS........................................................................................... 487 GENERAL INFORMATION.................................................................................. 487 TIRES................................................................................................ 487 Handling Tires................................................................................... 487 Tire Maintenance................................................................................. 488 Storing Tires After Removal...................................................................... 488 FRONT TIRES AND RIMS................................................................................. 489 Removal.......................................................................................... 489 Installation..................................................................................... 490 REAR TIRES AND RIMS.................................................................................. 491 Removal.......................................................................................... 491 Installation..................................................................................... 492 RIM.............................................................................................. 493 Tire Removal..................................................................................... 493 RIM AND TIRE PREPARATION............................................................................. 494 LUBRICANTS........................................................................................... 494 TIRE INSTALLATION.................................................................................... 495 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX............................................................. 497 FRONT WHEEL HUB AND SPINDLE.............................................................................. 499 WHEEL HUB AND SPINDLE ASSEMBLY....................................................................... 499 Removal.......................................................................................... 499 Installation..................................................................................... 501 Disassembly...................................................................................... 502 Cleaning and Inspection.......................................................................... 503 Assembly......................................................................................... 503 Wheel Bearing Adjustment (Spindle Vertical)...................................................... 506 Wheel Bearing Adjustment (Tire Mounted).......................................................... 507 STEERING CYLINDERS AND TIE ROD....................................................................... 508 Spherical Bearing Wear Limits.................................................................... 508 Removal.......................................................................................... 509 Installation..................................................................................... 511 Bearing Replacement.............................................................................. 511 TOE-IN ADJUSTMENT.................................................................................... 512 SECTION G4 - REAR AXLE HOUSING ATTACHMENTS - INDEX........................................................... 513 REAR AXLE HOUSING........................................................................................ 515 PIVOT PIN............................................................................................ 515 Removal.......................................................................................... 515 Installation..................................................................................... 516 PIVOT EYE BEARING.................................................................................... 516 Disassembly...................................................................................... 516 Assembly......................................................................................... 517 PIVOT EYE REPAIR..................................................................................... 517 Removal.......................................................................................... 517 Disassembly...................................................................................... 517 Bushing (New).................................................................................... 517 Pivot Eye Bore (New)............................................................................. 517 Assembly......................................................................................... 517 Installation..................................................................................... 518 ANTI-SWAY BAR........................................................................................ 518 Removal.......................................................................................... 518 Installation..................................................................................... 518 Disassembly...................................................................................... 519 Cleaning and Inspection.......................................................................... 519 Assembly......................................................................................... 519 SECTION G5 - REAR AXLE HOUSING - INDEX....................................................................... 521 REAR AXLE HOUSING........................................................................................ 523 REAR AXLE HOUSING.................................................................................... 523 Removal.......................................................................................... 523 Installation..................................................................................... 523 WHEEL MOTOR.......................................................................................... 523 Removal.......................................................................................... 523 Cleaning and Inspection.......................................................................... 524 Installation..................................................................................... 524 Maximum Cap Screw Usage.......................................................................... 524 REAR AXLE HOUSING BUMPER PAD......................................................................... 525 SECTION H - SUSPENSIONS - INDEX.................................................................................. 527 SECTION H2 - FRONT SUSPENSIONS - INDEX....................................................................... 529 FRONT SUSPENSION......................................................................................... 531 Removal.............................................................................................. 531 Installation......................................................................................... 533 Turn-of-the-Nut Tightening Procedure................................................................. 534 Disassembly.......................................................................................... 535 Cleaning and Inspection.............................................................................. 536 Assembly (Bearing Only).............................................................................. 536 Suspension Assembly (Complete)....................................................................... 536 SUSPENSION PRESSURE TEST............................................................................. 538 SECTION H3 - REAR SUSPENSIONS - INDEX........................................................................ 541 REAR SUSPENSIONS......................................................................................... 543 Removal.............................................................................................. 544 Installation......................................................................................... 546 Disassembly.......................................................................................... 546 Cleaning and Inspection.............................................................................. 546 Assembly............................................................................................. 547 SUSPENSION PRESSURE TEST............................................................................. 549 SECTION H4 - OILING AND CHARGING PROCEDURE - INDEX........................................................... 551 OILING AND CHARGING PROCEDURE............................................................................ 553 GENERAL.............................................................................................. 553 EQUIPMENT LIST....................................................................................... 553 Hydrair® Charging Kit............................................................................ 553 Installation of Charging Kit..................................................................... 553 Removal of Charging Kit.......................................................................... 554 Support Blocks For Oiling and Charging Dimensions................................................ 554 FRONT SUSPENSION..................................................................................... 555 Front Suspension Oiling.......................................................................... 555 Front Suspension Nitrogen Charging............................................................... 556 REAR SUSPENSION...................................................................................... 558 Rear Suspension Oiling........................................................................... 558 Rear Suspension Nitrogen Charging................................................................ 560 OIL AND NITROGEN SPECIFICATIONS CHART.................................................................... 561 SECTION J - BRAKE CIRCUIT - INDEX................................................................................ 563 SECTION J2 - BRAKE CIRCUIT - INDEX........................................................................... 565 BRAKE CIRCUIT............................................................................................ 567 GENERAL DESCRIPTION.................................................................................. 567 SERVICE BRAKE CIRCUIT................................................................................ 567 SECONDARY BRAKING AND AUTOMATIC APPLY................................................................ 569 PARKING BRAKE CIRCUIT................................................................................ 569 Normal Operation (key switch on, engine on)...................................................... 569 BRAKE LOCK CIRCUIT................................................................................... 570 WARNING CIRCUIT...................................................................................... 570 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX......................................................... 573 BRAKE CIRCUIT COMPONENT SERVICE.......................................................................... 575 BRAKE VALVE.......................................................................................... 575 Rebuild Criteria................................................................................. 575 Removal.......................................................................................... 576 Installation..................................................................................... 576 DISASSEMBLY.......................................................................................... 578 Cleaning and Inspection.......................................................................... 579 ASSEMBLY............................................................................................. 581 Actuator Base Threaded Inserts................................................................... 581 Boot and Cap..................................................................................... 581 Valve Body Seal Installation..................................................................... 582 Regulator Sleeve O-Ring Installation............................................................. 582 Actuator Plunger O-ring Installation............................................................. 582 Assembly of Valve................................................................................ 582 DIFFERENTIAL PRESSURE SWITCH......................................................................... 584 Disassembly...................................................................................... 584 Cleaning and Inspection.......................................................................... 584 Assembly......................................................................................... 584 VALVE BENCH TEST AND ADJUSTMENT...................................................................... 585 Test Set Up Procedure............................................................................ 585 Brake Valve Output Pressure Adjustment........................................................... 587 Differential Pressure Switch Test................................................................ 588 Final Test and Adjustment........................................................................ 588 Installation Of Brake Pedal Actuator Assembly to Brake Valve..................................... 589 HYDRAULIC BRAKE ACCUMULATORS......................................................................... 591 Brake Accumulator Bleed Down Procedure........................................................... 591 Removal.......................................................................................... 591 Installation..................................................................................... 591 Disassembly...................................................................................... 592 Cleaning and Inspection.......................................................................... 593 Assembly......................................................................................... 593 Leak Testing..................................................................................... 595 BRAKE ACCUMULATOR CHARGING........................................................................... 596 Temperature During Precharge..................................................................... 598 ACCUMULATOR STORAGE.................................................................................. 599 Installation..................................................................................... 599 Bladder Storage.................................................................................. 600 BRAKE MANIFOLD....................................................................................... 600 Removal.......................................................................................... 600 Removal.......................................................................................... 600 Installation..................................................................................... 601 Disassembly...................................................................................... 601 Cleaning and Inspection.......................................................................... 601 Assembly......................................................................................... 602 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX....................................................... 603 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................................ 605 EQUIPMENT REQUIRED................................................................................... 608 INITIAL SYSTEM SET-UP................................................................................ 609 Parking Brake.................................................................................... 609 Service Brakes................................................................................... 610 Brake Lock/Secondary............................................................................. 610 Low Brake Pressure and Auto Apply................................................................ 611 Reapplications................................................................................... 611 Differential Pressure Switch..................................................................... 611 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................................ 613 CHECK-OUT PROCEDURE...................................................................................... 616 HYDRAULIC BRAKE SYSTEM DATA SHEET........................................................................ 616 SECTION J5 - FRONT DISC BRAKES - INDEX....................................................................... 619 FRONT DISC BRAKES........................................................................................ 621 BRAKE CALIPER........................................................................................ 621 Removal.......................................................................................... 621 Installation..................................................................................... 622 Disassembly...................................................................................... 623 Cleaning and Inspection.......................................................................... 623 Assembly......................................................................................... 625 BRAKE LINING......................................................................................... 625 Replacement...................................................................................... 625 FRONT SERVICE BRAKE BURNISHING....................................................................... 627 BRAKE BLEEDING PROCEDURE......................................................................... 628 REAR DISC BRAKES......................................................................................... 631 REAR BRAKES.......................................................................................... 631 CALIPER, DISC, AND PARKING BRAKE..................................................................... 631 Removal.......................................................................................... 631 Installation..................................................................................... 632 Trucks equipped with one-piece adapter........................................................... 635 Removal.......................................................................................... 635 Installation..................................................................................... 636 CALIPER PISTON....................................................................................... 637 Piston Assembly Removal.......................................................................... 637 Inspection....................................................................................... 637 Piston Assembly Installation..................................................................... 638 FUNCTIONAL TEST OF PISTON ASSEMBLY................................................................... 639 Return Spring Force.............................................................................. 639 Built-In Clearance............................................................................... 639 Grip Force....................................................................................... 640 Grip Force Measurement........................................................................... 642 Spring Force Measurement......................................................................... 643 Disassembly of Piston Assembly................................................................... 644 Assembly of Piston Assembly...................................................................... 645 BENCH TEST........................................................................................... 645 BRAKE LINING......................................................................................... 646 Replacement...................................................................................... 646 SERVICE BRAKE BURNISHING............................................................................. 649 SAFETY PRECAUTIONS............................................................................... 649 Rear Brake Conditioning...................................................................... 650 BRAKE BLEEDING PROCEDURE......................................................................... 651 Spring Force Measurement..................................................................... 652 SECTION J6 - REAR BRAKES - INDEX............................................................................. 629 SECTION J7 - PARKING BRAKE - INDEX........................................................................... 653 PARKING BRAKE............................................................................................ 655 GENERAL INFORMATION.................................................................................. 655 PARKING BRAKE CALIPER................................................................................ 655 Lining Thickness Inspection...................................................................... 655 Removal.......................................................................................... 656 Installation..................................................................................... 656 Parking Brake Adjustment......................................................................... 657 Parking Brake Caliper Disassembly................................................................ 658 Cleaning and Inspection.......................................................................... 659 Parking Brake Caliper Assembly................................................................... 660 PARKING BRAKE LINING REPLACEMENT..................................................................... 660 PARKING BRAKE BURNISH PROCEDURE...................................................................... 660 Lining Conditioning.............................................................................. 660 BRAKE BLEEDING PROCEDURE............................................................................. 661 SECTION L - HYDRAULIC SYSTEM - INDEX............................................................................. 663 SECTION L2 - HYDRAULIC SYSTEM OVERVIEW - INDEX............................................................... 665 HYDRAULIC SYSTEM OVERVIEW................................................................................ 667 Hoist Circuit Operation.............................................................................. 667 Steering, Brake and Pantograph Circuit Operation..................................................... 667 Axle Blower System Operation......................................................................... 671 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX....................................................... 673 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................................ 675 HOIST PUMP........................................................................................... 675 Removal.......................................................................................... 675 Installation..................................................................................... 677 Disassembly...................................................................................... 677 Inspection....................................................................................... 680 Assembly......................................................................................... 681 PISTON PUMP...................................................................................... 686 Removal...................................................................................... 686 Installation................................................................................. 687 Disassembly.................................................................................. 689 Inspection of Parts.......................................................................... 695 Assembly..................................................................................... 697 AXLE BLOWER HYDRAULIC MOTOR.............................................................................. 702 Removal.............................................................................................. 702 Installation......................................................................................... 702 Rear Axle Blower Housing............................................................................. 702 Disassembly...................................................................................... 702 Assembly......................................................................................... 703 Disassembly...................................................................................... 705 Inspection....................................................................................... 707 Assembly......................................................................................... 708 Trouble Shooting................................................................................. 709 Hand Wheel Control................................................................................... 710 Disassembly...................................................................................... 710 Assembly......................................................................................... 710 HYDRAULIC TANK....................................................................................... 712 Filling Instructions............................................................................. 712 Removal.......................................................................................... 713 Installation..................................................................................... 713 HYDRAULIC TANK STRAINER AND DIFFUSER................................................................. 713 Removal.......................................................................................... 713 Inspect and Clean................................................................................ 714 Installation..................................................................................... 714 SECTION L4 - STEERING CIRCUIT - INDEX........................................................................ 715 STEERING CIRCUIT......................................................................................... 717 STEERING CIRCUIT OPERATION........................................................................... 717 COMPONENT DESCRIPTION................................................................................ 718 Steering Control Valve........................................................................... 718 Unloader Valve................................................................................... 719 Bleed-Down Manifold Valve........................................................................ 719 Flow Amplifier................................................................................... 725 FLOW AMPLIFIER SYSTEM OPERATION...................................................................... 726 No Steer......................................................................................... 726 Steering Left.................................................................................... 728 Steering Right................................................................................... 730 No Steer, External Shock Load.................................................................... 732 Steering Pump.................................................................................... 734 High Pressure Filter............................................................................. 734 Accumulators..................................................................................... 734 Low Precharge Warning Switch..................................................................... 734 SECTION L5 - STEERING CONTROL VALVE - INDEX.................................................................. 735 STEERING CONTROL VALVE................................................................................... 737 Removal.............................................................................................. 737 Installation......................................................................................... 738 STEERING CONTROL VALVE REBUILD....................................................................... 739 Disassembly...................................................................................... 739 Cleaning and Inspection.......................................................................... 740 Assembly......................................................................................... 740 BRAKE / STEERING PUMP................................................................................ 744 Removal.......................................................................................... 744 Installation..................................................................................... 746 Disassembly...................................................................................... 747 Inspection of Parts.............................................................................. 747 Assembly......................................................................................... 749 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX....................................................... 751 STEERING CIRCUIT COMPONENT REPAIR........................................................................ 753 BLEED DOWN MANIFOLD.................................................................................. 753 Removal.......................................................................................... 753 Installation..................................................................................... 753 ACCUMULATOR.......................................................................................... 754 Removal.......................................................................................... 754 Installation..................................................................................... 755 Disassembly...................................................................................... 756 Cleaning and Inspection.......................................................................... 756 Assembly......................................................................................... 756 LEAK TESTING......................................................................................... 758 STEERING ACCUMULATOR CHARGING PROCEDURE.............................................................. 759 Temperature During Precharge..................................................................... 762 ACCUMULATOR STORAGE PROCEDURES....................................................................... 763 Instructions For Storing Bladder Accumulators.................................................... 763 Instructions For Installing A Bladder Accumulator That Was In A Parts Warehouse Or In Storage.... 763 Bladder Storage Procedures....................................................................... 764 FLOW AMPLIFIER....................................................................................... 764 Removal.......................................................................................... 764 Installation..................................................................................... 764 Disassembly...................................................................................... 764 Assembly......................................................................................... 767 STEERING CYLINDERS................................................................................... 769 Disassembly...................................................................................... 769 Piston Seal & Bearing Installation............................................................... 769 Cylinder Assembly................................................................................ 769 Test............................................................................................. 769 TROUBLESHOOTING CHART................................................................................ 772 SECTION L7 - HOIST CIRCUIT - INDEX........................................................................... 777 HOIST CIRCUIT............................................................................................ 779 COMPONENT DESCRIPTION................................................................................ 780 HYDRAULIC TANK................................................................................... 780 HYDRAULIC PUMP................................................................................... 780 HIGH PRESSURE FILTER............................................................................. 780 HOIST VALVE...................................................................................... 780 HOIST PILOT VALVE................................................................................ 782 BLEEDDOWN MANIFOLD............................................................................... 782 COUNTERBALANCE VALVE MANIFOLD.................................................................... 782 HOIST-UP LIMIT SOLENOID.......................................................................... 782 PILOT OPERATED CHECK VALVE....................................................................... 783 HOIST VALVE OPERATION............................................................................ 783 FLOAT OPERATION.............................................................................. 783 POWER UP OPERATION (Figure 7-5).............................................................. 786 HOLD OPERATION (Figure 7-6).................................................................. 788 POWER DOWN OPERATION (Figure 7-7)............................................................ 790 FLOAT OPERATION (Figure 7-8)................................................................. 791 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX.......................................................... 795 HOIST CIRCUIT COMPONENT REPAIR........................................................................... 797 HOIST VALVE.......................................................................................... 797 Removal.......................................................................................... 797 Installation..................................................................................... 797 O-Ring Replacement............................................................................... 799 INLET SECTION........................................................................................ 800 Disassembly...................................................................................... 800 Cleaning and Inspection.......................................................................... 801 Assembly......................................................................................... 801 REAR SPOOL SECTION (WORK PORTS)...................................................................... 802 Disassembly...................................................................................... 802 Cleaning and Inspection.......................................................................... 804 Assembly......................................................................................... 804 HOIST PILOT VALVE.................................................................................... 806 Removal.......................................................................................... 806 Installation..................................................................................... 806 Disassembly...................................................................................... 807 Cleaning and Inspection.......................................................................... 808 Assembly......................................................................................... 808 HOIST UP LIMIT SOLENOID VALVE........................................................................ 809 HOIST CYLINDERS...................................................................................... 809 Removal.......................................................................................... 809 Installation..................................................................................... 810 Disassembly...................................................................................... 813 Cleaning and Inspection.......................................................................... 814 SS1143 Tightening Tool - Assembly Drawing........................................................ 815 ASSEMBLY OF QUILL AND CYLINDER....................................................................... 815 Quill Installation............................................................................... 815 Installation Of Check Balls And Plugs In Quill................................................... 816 Assembly of Cylinder............................................................................. 818 COUNTERBALANCE MANIFOLD.............................................................................. 819 SECTION L9 - HIGH PRESSURE FILTERS - INDEX................................................................... 821 HYDRAULIC SYSTEM FILTERS................................................................................. 823 HOIST CIRCUIT FILTER................................................................................. 823 Filter Element Replacement....................................................................... 823 Removal.......................................................................................... 824 Installation..................................................................................... 824 Indicator Switch................................................................................. 824 STEERING CIRCUIT FILTER.............................................................................. 825 Filter Element Replacement....................................................................... 825 Removal.......................................................................................... 826 Installation..................................................................................... 826 Indicator Switch................................................................................. 826 INDICATOR SWITCH..................................................................................... 826 Test Procedure................................................................................... 826 SECTION L10 - HYDRAULIC CHECKOUT PROCEDURE - INDEX........................................................... 829 HYDRAULIC CHECKOUT PROCEDURE............................................................................. 831 Initial Start Up and Flushing (Steps 5 - 22)......................................................... 832 Component Checkout and Adjustment (Steps 23 - 34).................................................... 834 Adjustment Procedure for Hoist Counterbalance Cartridge Valve (Steps 34a-34l)........................ 836 Counterbalance Valve Adjustment (Steps f & g):................................................... 838 Manifold reassembly (steps i through k):......................................................... 838 Piston Pump and Axle Box Hydraulic Motor Adjustment (Steps 35 - 50).................................. 838 Oil Cleanliness Check................................................................................ 839 Oil Sampling Location on Truck:.................................................................. 839 Oil Sampling Process and Cleanliness Criteria:................................................... 839 DISABLED TRUCK DUMPING PROCEDURE..................................................................... 840 HOOKUP........................................................................................... 840 DUMPING PROCEDURE................................................................................ 840 Raising the Body:................................................................................ 840 Lowering the Body:............................................................................... 841 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX.................................................................... 849 SECTION M4 - ELECTRIC DRIVE COOLING AIR FILTER SYSTEM - INDEX................................................ 851 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM................................................................. 853 SYSTEM ADJUSTMENT.................................................................................... 853 PUMP................................................................................................. 856 Removal.............................................................................................. 856 Disassembly.......................................................................................... 856 Inspection........................................................................................... 856 Assembly............................................................................................. 856 Installation......................................................................................... 856 BLOWER DRIVE MOTOR................................................................................... 859 Removal.............................................................................................. 859 Disassembly.......................................................................................... 859 Inspection Of Parts.................................................................................. 860 Assembly............................................................................................. 861 Installation......................................................................................... 862 BLOWER BEARING REPAIR................................................................................ 862 Removal.......................................................................................... 862 Replacement...................................................................................... 862 Assembly......................................................................................... 863 AIR CLEANER.......................................................................................... 863 Assembly......................................................................................... 863 Removal.......................................................................................... 863 Assembly......................................................................................... 863 SECTION M7 - ENGINE OIL HEATER - INDEX....................................................................... 865 ENGINE OIL HEATERS....................................................................................... 867 GENERAL INFORMATION.................................................................................. 867 TROUBLESHOOTING...................................................................................... 867 HEATER ELEMENT....................................................................................... 867 Removal.......................................................................................... 867 Installation..................................................................................... 868 SECTION M8 - SPECIAL TOOLS................................................................................... 869 SECTION N - OPERATOR'S CAB - INDEX............................................................................... 879 SECTION N2................................................................................................... 881 TRUCK CAB................................................................................................ 883 TRUCK CAB............................................................................................ 883 Description...................................................................................... 883 Removal.......................................................................................... 884 Installation..................................................................................... 886 CAB DOOR............................................................................................. 886 Removal.......................................................................................... 886 Installation..................................................................................... 887 Door Adjustment.................................................................................. 887 Door Jam Bolt Adjustment......................................................................... 887 Door Handle Plunger Adjustment................................................................... 889 Replace Door Glass............................................................................... 890 Replace Door Window Regulator.................................................................... 894 Replace Door Handle or Latch Assembly............................................................ 894 Door and Door Hinge Seal Replacement............................................................. 895 Door Opening Seal Removal........................................................................ 895 Installation..................................................................................... 895 GLASS REPLACEMENT.................................................................................... 896 Adhesive-Bonded Windows.......................................................................... 896 Recommended Tools/Supplies....................................................................... 896 Replacement Procedure............................................................................ 896 Windshield and Rear Glass........................................................................ 897 Removal.......................................................................................... 897 Installation..................................................................................... 898 SECTION N3 - CAB COMPONENTS - INDEX.......................................................................... 899 CAB COMPONENTS........................................................................................... 901 WINDSHIELD WIPERS.................................................................................... 901 WIPER MOTOR REPLACEMENT.......................................................................... 901 Removal...................................................................................... 901 Installation................................................................................. 901 WIPER ARM REPLACEMENT............................................................................ 901 Removal...................................................................................... 901 Installation................................................................................. 902 WIPER LINKAGE REPLACEMENT........................................................................ 902 Removal...................................................................................... 902 Installation................................................................................. 903 WINDSHIELD WASHER................................................................................ 903 Operation.................................................................................... 903 Service...................................................................................... 903 SECTION N4 - OPERATOR COMFORT - INDEX........................................................................ 905 HEATER/AIR CONDITIONER................................................................................... 907 CONTROLS............................................................................................. 907 Operation........................................................................................ 907 Heater/Air Conditioner Vents..................................................................... 907 Defroster Vent Control Switch.................................................................... 907 Heat Control Switch.............................................................................. 907 Temperature Control Knob......................................................................... 907 Fan Control Knob................................................................................. 907 Heater/Air Conditioner Selector Switch........................................................... 907 COMPONENTS........................................................................................... 908 Circuit Breakers................................................................................. 908 Relays........................................................................................... 908 Heater Core...................................................................................... 908 Fan Motor and Speed Control...................................................................... 909 Test............................................................................................. 909 Actuators........................................................................................ 909 Test............................................................................................. 909 Cab Air Filter................................................................................... 910 AIR CONDITIONING SYSTEM.................................................................................. 912 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................................ 913 PRINCIPLES OF REFRIGERATION.......................................................................... 913 Air Conditioning................................................................................. 913 Refrigeration - The Act of Cooling............................................................... 914 The Refrigeration Cycle.......................................................................... 914 AIR CONDITIONER SYSTEM COMPONENTS.................................................................... 915 Compressor (Refrigerant Pump).................................................................... 915 Service Valves................................................................................... 915 Receiver-Drier................................................................................... 915 Condenser........................................................................................ 915 Expansion Block Valve............................................................................ 916 Accumulator...................................................................................... 916 Evaporator....................................................................................... 917 ELECTRICAL CIRCUIT................................................................................... 917 Thermostat....................................................................................... 917 Compressor Clutch................................................................................ 918 Trinary™ Switch.................................................................................. 918 SYSTEM SERVICING..................................................................................... 920 SERVICE TOOLS AND EQUIPMENT.......................................................................... 921 Recovery/Recycle Station......................................................................... 921 Leak Detector.................................................................................... 922 Service Valves................................................................................... 922 Vacuum Pump...................................................................................... 922 Manifold Gauge Set............................................................................... 923 Low Side Gauge................................................................................... 923 High Side Gauge.................................................................................. 923 Installing Manifold Gauge Set.................................................................... 924 Purging Air From Service Hoses................................................................... 924 SYSTEM PERFORMANCE TEST.............................................................................. 925 SYSTEM OIL........................................................................................... 926 Handling and Reusing RPAG Oil.................................................................... 926 Oil Quantity..................................................................................... 926 Checking System Oil.............................................................................. 926 REFRIGERANT.......................................................................................... 927 Recycled Refrigerant............................................................................. 927 Reclaimed Refrigerant............................................................................ 927 Refrigerant Quantity............................................................................. 928 R-134a Refrigerant Containers.................................................................... 928 SYSTEM LEAK TESTING.................................................................................. 928 Electronic Leak Detector......................................................................... 929 Tracer Dyes...................................................................................... 929 Soap and Water................................................................................... 929 RECOVERING AND RECYCLING THE REFRIGERANT............................................................. 930 Performing the Recovery Cycle.................................................................... 930 Performing the Recycling Procedure............................................................... 930 Evacuating and Charging the A/C System........................................................... 930 SYSTEM REPAIR........................................................................................ 931 System Flushing.................................................................................. 931 COMPONENT REPLACEMENT................................................................................ 932 Hoses and Fittings............................................................................... 932 Lines............................................................................................ 932 Expansion Valve.................................................................................. 932 Receiver-Drier................................................................................... 932 Thermostat....................................................................................... 932 Compressor....................................................................................... 933 Accumulator...................................................................................... 933 Clutch........................................................................................... 933 Servicing the Compressor Clutch.................................................................. 934 Pulley Removal................................................................................... 936 Clutch Coil Check................................................................................ 937 Pulley Installation.............................................................................. 937 Clutch Assembly Installation..................................................................... 938 EVACUATING THE SYSTEM................................................................................ 939 CHARGING THE A/C SYSTEM.............................................................................. 941 AIR CONDITIONER DRIVE BELT........................................................................... 942 Pulley Alignment................................................................................. 942 Belt Tension..................................................................................... 943 TROUBLESHOOTING...................................................................................... 944 Preliminary Checks............................................................................... 944 Diagnosis of Gauge Readings and System Performance............................................... 944 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS....................................................... 945 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................................... 951 SECTION N5 - OPERATOR CONTROLS - INDEX....................................................................... 953 OPERATOR CONTROLS........................................................................................ 955 STEERING WHEEL AND CONTROLS.......................................................................... 956 STEERING WHEEL................................................................................... 956 HORN BUTTON...................................................................................... 956 TILT/TELESCOPE LEVER............................................................................. 956 MULTI-FUNCTION TURN SIGNAL SWITCH................................................................ 956 Turn Signal Operation........................................................................ 957 High Beam Headlight Operation................................................................ 957 Windshield Wiper Operation................................................................... 957 STEERING COLUMN.................................................................................. 957 Removal...................................................................................... 957 Inspection................................................................................... 958 Installation................................................................................. 958 PEDALS............................................................................................... 958 SERVICE BRAKE PEDAL.............................................................................. 958 DYNAMIC RETARDER PEDAL........................................................................... 959 Optional - Dual Function/Single Pedal........................................................ 959 THROTTLE PEDAL................................................................................... 959 OVERHEAD PANEL CONTROLS AND COMPONENTS............................................................... 960 GRADE/SPEED WARNING CHART........................................................................ 960 RADIO SPEAKERS................................................................................... 960 WINDSHIELD WIPERS................................................................................ 960 WARNING ALARM BUZZER............................................................................. 960 CAB RADIO........................................................................................ 960 WARNING LIGHTS DIMMER CONTROL.................................................................... 960 WARNING/STATUS INDICATOR LIGHT PANEL............................................................. 960 AIR CLEANER VACUUM GAUGES........................................................................ 960 CENTER CONSOLE....................................................................................... 961 TRUCK CONTROLS................................................................................... 961 F-N-R Selector Switch........................................................................ 961 Hoist Control Lever.......................................................................... 961 Trolley Master Control Lever................................................................. 961 CONSOLE SWITCHES AND CONTROLS.................................................................... 961 Cigarette Lighter............................................................................ 961 Window Control Switches...................................................................... 961 Engine Shutdown Switch....................................................................... 961 Override Switch.............................................................................. 963 Retard Speed Control (RSC) Switch............................................................ 963 Retard Speed Control (RSC) Dial.............................................................. 963 Statex III Download Port..................................................................... 964 Engine Diagnostic Port (CENSE)............................................................... 964 Engine Diagnostic Connectors................................................................. 964 Data Storage Button.......................................................................... 964 Passenger Seat............................................................................... 964 PAYLOAD METER.................................................................................... 965 Payload Meter Download Connector............................................................. 965 CAB CLIMATE CONTROL.................................................................................. 966 HEATER/AIR CONDITIONER VENTS..................................................................... 966 HEATER/AIR CONDITIONER CONTROLS AND VENTS........................................................ 966 Defroster Vent Control Switch................................................................ 966 Heat Control Switch.......................................................................... 966 Temperature Control Knob..................................................................... 966 Fan Control Knob............................................................................. 966 Heater/Air Conditioner Vents................................................................. 966 OPERATOR SEAT........................................................................................ 967 ADJUSTMENT....................................................................................... 967 INSTRUMENT PANEL..................................................................................... 968 GENERAL INFORMATION.............................................................................. 968 CONTROL SYMBOLS.................................................................................. 968 CONTROL SWITCHES AND GAUGES...................................................................... 969 Key Switch................................................................................... 969 Engine Shutdown Switch With Timer Delay...................................................... 969 Fog Light Switch............................................................................. 971 Ladder Light Switch.......................................................................... 971 Backup Light Switch.......................................................................... 971 Panel Illumination Lights.................................................................... 971 Cab Air Conditioner/Heater Vents............................................................. 971 Engine Cold Weather Starting Aid Switch...................................................... 971 Rotating Beacon Light Switch................................................................. 971 Heated Mirror Switch......................................................................... 971 Wheel Brake Lock Switch...................................................................... 971 Parking Brake Switch......................................................................... 972 Digital Tachometer........................................................................... 972 Right Turn Signal Indicator Light............................................................ 972 High Beam Headlight Indicator Light.......................................................... 972 Left Turn Signal Indicator Light............................................................. 972 Digital Speedometer/Payload Meter Display.................................................... 972 Voltmeter Gauge.............................................................................. 973 Engine Oil Pressure Gauge.................................................................... 973 Engine Water Temperature Gauge............................................................... 973 Fuel Gauge................................................................................... 973 Engine Hourmeter............................................................................. 973 Headlight Switch............................................................................. 973 Panel Illumination Lights Dimmer Rheostat.................................................... 973 Payload Meter Switch......................................................................... 974 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL...................................................... 974 INDICATOR LIGHT FUNCTIONS........................................................................ 975 High Hydraulic Oil Temperature............................................................... 975 Low Steering Pressure........................................................................ 975 Low Accumulator Precharge Pressure Warning................................................... 976 Electric System Fault Warning................................................................ 976 Low Brake Pressure Indicator................................................................. 976 Low Hydraulic Tank Level..................................................................... 976 Low Automatic Lubrication System Pressure.................................................... 977 Circuit Breaker Tripped...................................................................... 977 Hydraulic Oil Filter......................................................................... 977 Low Fuel Indicator........................................................................... 977 Parking Brake Indicator...................................................................... 977 Service Brake Indicator...................................................................... 977 Body Up Indicator............................................................................ 977 Dynamic Retarding Indicator.................................................................. 977 Stop Engine Warning.......................................................................... 978 Backup Indicator............................................................................. 978 Engine Shutdown Timer Switch- Five Minute Idle............................................... 978 Retard Speed Control......................................................................... 978 Service Engine Indicator (AEM)............................................................... 978 High Wheel Motor Temperature Indicator....................................................... 978 Blower Fault Warning......................................................................... 978 Service Engine Indicator (CENSE)............................................................. 978 Komatsu Engines w/Centry™ Fuel Control....................................................... 979 Hazard Warning Light Switch.................................................................. 979 Lamp Test Switch/Centry™ Diagnostic Test Switch.............................................. 979 CENTRY™ FUEL SYSTEM DIAGNOSTICS...................................................................... 982 GENERAL OPERATION................................................................................ 982 DETERMINING FAULT CODES.......................................................................... 983 EXITING THE DIAGNOSTICS MODE..................................................................... 984 SECTION P - LUBRICATION AND SERVICE - INDEX...................................................................... 985 SECTION P2 - LUBRICATION AND SERVICE - INDEX................................................................. 987 LUBRICATION AND SERVICE.................................................................................. 989 GENERAL INFORMATION.................................................................................. 989 HYDRAULIC TANK SERVICE............................................................................... 989 Adding Oil....................................................................................... 989 COOLING SYSTEM....................................................................................... 990 Coolant Level Check.............................................................................. 990 Radiator Filling Procedure....................................................................... 990 Antifreeze Temperature Recommendations........................................................... 990 10 HOUR LUBE AND MAINTENANCE CHECKS...................................................................... 992 50 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................................... 993 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................. 993 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................. 994 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................. 996 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................................. 997 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................................. 998 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................................. 998 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................................. 999 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................... 999 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX............................................................1001 AUTOMATIC LUBRICATION SYSTEM.............................................................................1003 GENERAL DESCRIPTION..................................................................................1003 SYSTEM COMPONENTS....................................................................................1004 Filter Assembly..................................................................................1004 Hydraulic Motor and Grease Pump..................................................................1004 Reservoir........................................................................................1005 Fixed Pressure Reducing Valve....................................................................1005 Flow Control Valve...............................................................................1005 Solenoid Valve...................................................................................1005 Vent Valve.......................................................................................1005 24VDC Lubrication Cycle Timer....................................................................1005 Time Delay Module................................................................................1005 Pump Cutoff Pressure Switch......................................................................1005 Unloader Valve...................................................................................1005 Pressure Switch..................................................................................1005 Pressure Gauge...................................................................................1007 Manual Override Button...........................................................................1007 Injectors........................................................................................1007 SYSTEM OPERATION.....................................................................................1009 Normal Operation.................................................................................1009 Pressure Failure Detection Circuits..............................................................1010 GENERAL INSTRUCTIONS.....................................................................................1011 LUBRICANT REQUIRED FOR SYSTEM........................................................................1011 SYSTEM PRIMING.......................................................................................1011 LUBRICANT PUMP.......................................................................................1012 Pump Housing Oil Level...........................................................................1012 Pump Pressure Control............................................................................1012 FILTER AND RESERVOIR.................................................................................1012 Filter Assembly Element..........................................................................1013 INJECTORS (SL-1 Series H)............................................................................1013 Injector Specifications..........................................................................1013 Injector Adjustment..............................................................................1013 INJECTOR OPERATION.......................................................................................1015 SYSTEM CHECKOUT......................................................................................1016 Lubrication Cycle Timer Check....................................................................1016 Lubrication Cycle Timer Adjustment...............................................................1017 PREVENTIVE MAINTENANCE INSPECTION....................................................................1017 10 Hour Lubrication System Inspection............................................................1017 100 Hour Inspection..............................................................................1017 250 Hour Inspection..............................................................................1017 500 Hour Inspection..............................................................................1018 1000 Hour Inspection.............................................................................1018 PUMP REBUILD.........................................................................................1019 Disassembly......................................................................................1019 Cleaning and Inspection..........................................................................1020 Assembly.........................................................................................1022 VENT VALVE REB UILD..................................................................................1023 Disassembly and Assembly.........................................................................1023 SYSTEM TROUBLESHOOTING CHART.........................................................................1024 SECTION P4 - MOTORIZED WHEEL MAINTENANCE SCHEDULE - INDEX....................................................1027 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................................................1029 AXLE BOX.............................................................................................1029 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................................................1030 ARMATURE AREA........................................................................................1030 AT TIRE CHANGE.......................................................................................1030 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................................................1031 GENERATOR/ALTERNATOR.................................................................................1031 GRID BLOWER MOTOR....................................................................................1031 CONTROL EQUIPMENT CHECKS.............................................................................1031 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................................................1032 VEHICLE OPERATIONS TESTS.............................................................................1032 SECTION R - SYSTEM SCHEMATICS - INDEX............................................................................1033 HYDRAULIC BRAKE SYSTEM SCHEMATIC.............................................................................1035 HYDRAULIC SYSTEM SCHEMATIC...................................................................................1036 ELECTRICAL SCHEMATIC ........................................................................................1037
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