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KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30392 & A30393 ) – PDF Download


  • KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL
  • Serial Number:A30392 & A30393 
  • Publication Number:CEBM018400

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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

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at heydownloadss@gmail.com should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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