Komatsu 630E Dump Truck Shop Manual – DG675

This Complete Service Repair Workshop Manual PDF Download for the Komatsu 630E Dump Truck has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu 630E Dump Truck
Serial Numbers : AFE42-M and up
Serial Numbers : AFE46-U and up

TABLE OF CONTENTS :

– GENERAL INFORMATION
– STRUCTURES
– ENGINE, FUEL, COOLING AND AIR CLEANER
– ELECTRIC SYSTEM (24 VDC. NON-PROPULSION
– ELECTRIC PROPULSION AND CONTROL
– DRIVE AXLE, SPINDLES AND WHEELS
– HYDRAIR II SUSPENSIONS
– BRAKE CIRCUIT
– AIR SYSTEM
– HYDRAULIC SYSTEM
– OPTIONS AND SPECIAL TOOLS
– OPERATORS CAB
– LUBRICATION AND SERVICE
– ALPHABETICAL INDEX
– SYSTEM SCHEMATICS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : DG675
Total Pages : 885

This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

–

COVER
FOREWORD
TABLE OF CONTENTS

SECTION A GENERAL INFORMATION INDEX
MAJOR COMPONENT DESCRIPTION
ENGINE
ALTERNATOR
WHEEL MOTORS (GE 776)
BLOWER
OPERATOR’S CAB
POWER STEERING
DYNAMIC RETARDING
BRAKE SYSTEM
SUSPENSION
GENERAL SAFETY AND OPERATION
SPECIFICATIONS
ENGINES (Standard Options)
Cummins KTTA 50-C
Detroit Diesel 16V-149TIB
ELECTRIC DRIVE SYSTEM
STATEX III AC/DC Current
DYNAMIC RETARDING
BATTERY ELECTRIC SYSTEM
SERVICE CAPACITIES
AIR SYSTEM
HYDRAULIC SYSTEM
SERVICE BRAKES
STEERING
DUMP BODY
TIRES
WEIGHT DISTRIBUTION
EMPTY
LOADED
OVERALL TRUCK DIMENSIONS
SAFETY IS THINKING AHEAD
Safe practices start before the operator gets to the equipment!
PREPARING FOR OPERATION
ENGINE START-UP SAFETY PRACTICES
AFTER ENGINE HAS STARTED
SAFETY PRECAUTIONS DURING TRUCK OPERATION
LOADING
HAULING
PASSING
DUMPING
To Raise dump body:
To Lower Body:
TOWING
WHEN REPAIRS ARE NECESSARY
SAFE PARKING PROCEDURES
SHUTDOWN PROCEDURE
WARNINGS AND CAUTIONS
STANDARD CHARTS AND TABLES
STORAGE PROCEDURES

SECTION B STRUCTURES INDEX
STRUCTURAL COMPONENTS
GRILLE AND HOOD
Removal
Installation
DECKS
Removal
Installation
DUMP BODY
DUMP BODY
Removal
Installation
BODY PAD
Body Pad Adjustment
BODY GUIDE
BODY POSITION INDICATOR
BODY SLING
Body Sling Hook-Up
ROCK EJECTORS
Inspection
BODY-UP LIMIT SWITCH
Indicator Arm Adjustment
FUEL TANK
FUEL TANK
Removal
Installation
Cleaning
BREATHER
GAUGE
Removal
Installation

SECTION C ENGINE INDEX
POWER MODULE
POWER MODULE
Removal
Installation
COOLING SYSTEM
RADIATOR
Removal
Service
Installation
Visual Inspection
Pressure Cap
Water Temperature Thermostats
POWER TRAIN
ALTERNATOR
Removal
Installation
ENGINE/ALTERNATOR MATING
Alternator End Play Measurement
Engine Endplay Measurement
Determining Shim Requirements
Installing Alternator on Engine
ENGINE
Removal
Service
Installation
FAN
AIR CLEANERS
FILTER ELEMENT REPLACEMENT
MAIN FILTER ELEMENT CLEANING
PRECLEANER SECTION
ENGINE COMPONENTS
THROTTLE CONTROL AIR CYLINDERS
Detroit Diesel Engine
Removal
Installation
Adjustment
Cummins Engine
Removal
Installation
Adjustment
LOW IDLE SOLENOID
Service
THROTTLE SOLENOID
Service
Operating Test

SECTION D ELECTRICAL SYSTEM INDEX
24 VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
BATTERY
Maintenance and Service
Troubleshooting
BATTERY CHARGING SYSTEM
General Description
Operating Principles
Energizing Speed
Rated Voltage
Magnetizing The Rotor
INTEGRAL CHARGING SYSTEM (Battery Charging Alternator)
Troubleshooting Procedures
Integral Charging System Repair
Regulator Check
Rectifier Bridge Check (Omit for Overcharged Battery)
Field Coil Checks
Diode Trio Check
Stator Checks (Omit for Overcharged Battery)
Disassembly (Refer to Figure 2-10)
Reassembly
24 VDC ELECTRICAL SYSTEM COMPONENTS
ALARM INDICATING DEVICE (AID) SYSTEM
BODY-UP SWITCH
Adjustment
Service
HOIST LIMIT SWITCH
Adjustment
Service
GROUND LEVEL SHUTDOWN
For Detroit Diesel (Without DDEC).
For Detroit Diesel (With DDEC II or DDEC III).
For Cummins Engines (With air throttle).
For Cummins Engines (With Centry throttle control).
24 VOLT RELAY BOARDS
Description
Service
RELAY BOARD DESCRIPTIONS
Relay Board 1 Turn Signal
Relay Board 2 Payload Meter (Optional)
Relay Board 3 Stop Lights
Relay Board 4 Parking Brake
Relay Board 5 Head Lights
Relay Board 6 Auxiliary Panel
DIODE BOARDS
Diode Board 1
Diode Board 2
CIRCUIT BREAKERS

SECTION E ELECTRICAL PROPULSION COMPONENTS INDEX
ELECTRICAL PROPULSION COMPONENTS
GENERAL SYSTEM DESCRIPTION
CONTROL SYSTEM
System Operation
17FL275 PANEL
COMPUTER DESCRIPTION
SOFTWARE
CARD REPLACEMENT
Removal
Installation
Card Repair
COMPUTER DESCRIPTION
Microprocessor
Download Capability
SOFTWARE
Base Monitor Program
Runtime Monitor Program – OBJ Running Code
Configuration Software – CFG
PTU – Portable Test Unit Code
System Regulation
Propulsion
Retarding
2-DIGIT DISPLAY PANEL
The Coded Number
Events
Frames
Windows
System Categories
Limits On Resetting Faults
Na Faults
Event Sequence
Resetting Events
Event Descriptions
Subcode Descriptions
2-DIGIT DISPLAY PANEL CODES
PORTABLE TEST UNIT (PTU)
DESCRIPTION
OPERATIONAL HINTS
SOFTWARE INSTALLATION PREPARATION
Deleting Prior Software Versions
Computer Boot File Editing
SOFTWARE INSTALLATION ON PTU
THE MAIN MENU
PTU SOFTWARE MENU TREE
CONFIGURATION (CFG) FILE CONVERSION
Conversion Procedure
STATEX CONFIGURATION FILES
“Change Ptu Password”
PROGRAMMING THE TRUCK
Connect PTU to the Truck
Select Configuration File
Activate The PTU Mode
Check Object Code Version
Download Configuration Files
Date And Time
Event Data
STATISTICAL DATA
“View Counters”
“View Profiles”
“Upload Statistical Data To A File”
Statistical Data Codes – Counters
STATISTICAL DATA CODES – PROFILES
Truck Specific Information
Temporary Truck Settings
MISCELLANEOUS FEATURES
Saving Data
Ptu Abbreviations
OTHER MENU SELECTIONS
PANEL WIRING
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS
ALTERNATOR
ELECTRIC WHEEL MOTORS
RETARDING GRIDS
AIR THROTTLE/ELECTRONIC RETARD CONTROL
Acceleration Switch [AS]
Range Adjustment
Differential Adjustment
Removal
Installation
Disassembly and Assembly
Adjustment Procedure (On Bench)
Adjustment Procedure (On Truck)
PROPEL/RETARD INTERFACE PANELS (Non-Fuel Saver Only)
ACC Panel Operation
RET Panel Operation
ELECTRONIC ACCELERATOR AND RETARD PEDALS
Removal
Installation
Disassembly
Assembly
COOLING BLOWER WARNING SYSTEM
Operation
Test
Removal
Installation
ELECTRICAL CONTROL CABINET
ABBREVIATION FOR STATEX III ELECTRIC DRIVE COMPONENTS
DETROIT DIESEL ELECTRONIC ENGINE CONTROLS ABBREBIATIONS
CARD IDENTIFICATION LIST GE17FL275 PANEL, STATEX III
CHECKOUT PROCEDURE STATEX III ELECTRICAL SYSTEM
GENERAL INFORMATION
COMMUNICATIONS PORT CHECK
PTU Hookup
1.0 SEQUENCE TESTS – (Engine not running)
1.1 Throttle System Check and Adjustment
1.1.1 Electronic Throttle System. (Williams electronic foot pedal, Dresser ACC/RET Interface Circuit and Pedal Detector Card).
1.1.2 Electronic Throttle System (Fuel Saver System).
1.2 Retard System Check and Adjustment
1.2.1 Williams Electronic Retard Pedal and Dresser ACC/RET or RET Interface Box.
1.2.2 Electronic Retard Pedal; Fuel Saver Equipped Trucks and Current Production.
1.3 Reverser and Propulsion Contactors Check
1.4 Propulsion Lockout Test (DDEC & MTU Engine Trucks Only)
1.5 Retard Contactors Operation Check
1.6 Ground Fault Sensing Check
1.7 Ground Fault in Retard Operation Check
1.8 Override Operation Check
1.9 Anti-Reversal Function (AR) Check
1.10 Overspeed Retard Operation Check
1.11 Hoist Interlock Operation Check
1.12 Motor Blower Fault Light Operation Check
2.0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL
2.1 Setup Manual Digital Input/Output Test on PTU
2.2 Digital Input Checks
2.3 Digital Output Checks
3.0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL
3.1 Setup Analog Input Monitor Screen on PTU
3.2 Analog Input Checks
3.3 Frequency Input Checks
4.0 SPEED EVENT CHECKS
4.1 Single Speed Overspeed Truck – Overspeed Settings Check
4.2 Two Speed Overspeed Truck (Empty Truck) – Overspeed Settings Check
4.3 Two Speed Overspeed Truck (Loaded Truck) – Overspeed Settings Check
4.4 Other Speed Events Checks
5.0 RETARD SPEED CONTROL SYSTEM CHECK
5.1 Overspeed Pickup and Dropout Check
5.2 Retard Pot Maximum Setting Check
5.3 Retard Pot Minimum Setting Check
5.4 Accelerator Pedal Override of Retard Speed Control
6.0 LOAD TEST USING TRUCK RETARD GRIDS
6.1 Load Test
7.0 MOTOR FIELD CURRENT CHECK IN RETARDING
7.1 Retard Check
8.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT
8.1 Brake System Interlocks Check
8.2 Blower Loss Pressure Switch Adjustment
8.3 SYNC Transformer Checkout
8.4 Power Contactor Position Sensor Adjustment
8.5 Battery Boost Adjustment
8.6 Isolation amplifier & voltage module test.
8.6.1 Voltage Measuring Module Test (VMM1 and VMM2)
8.6.2 ISOA3, ISOA4, ISOA5, ISOA6, ISOA-7, and ISOA-8 Test.
8.7 Motor Rotation Test
8.8 Ground Fault Checks
9.0 MISCELLANEOUS CHARTS
9.1 Wheel Motor Gear Ratios
9.2 Maximum Allowable Truck Speeds
9.3 Engine Options

SECTION G REAR AXLE SPINDLES AND WHEELS INDEX
TIRES AND RIMS
FRONT TIRES AND RIMS
Removal
Installation
REAR TIRE AND RIM
Removal
Installation
RIM
Tire Removal
Tire Installation
FRONT WHEEL HUB AND SPINDLE
FRONT WHEEL HUB
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Wheel Bearing Adjustment
Field Adjustment
STEERING CYLINDERS AND TIE ROD
Removal
Installation
Bearing Replacement
TOE-IN ADJUSTMENT
(Bias Ply Tires)
(Radial Tires)
REAR AXLE HOUSING ATTACHMENT
HITCH PIN
Removal
Installation
PIVOT PIN BEARING
Disassembly
Assembly
PIVOT EYE REPAIR
Removal
Installation
ANTI-SWAY BAR
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
REAR AXLE HOUSING
REAR AXLE HOUSING
WHEEL MOTOR
REAR AXLE HOUSING BUMPER PAD

SECTION H HYDRAIR II SUSPENSIONS INDEX
FRONT SUSPENSION
FRONT SUSPENSION
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
REAR SUSPENSION
REAR SUSPENSION
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
OILING AND CHARGING PROCEDURES
GENERAL
EQUIPMENT LIST
HYDRAIR® CHARGING KIT
Installation of Charging Kit
Removal of Charging Kit
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS
FRONT SUSPENSION
Front Suspension Oiling
Front Suspension Nitrogen Charging
REAR SUSPENSION
Rear Suspension Oiling
Rear Suspension Nitrogen Charging

SECTION J BRAKE CIRCUIT INDEX
BRAKE CIRCUIT
Operation
BRAKE CIRCUIT COMPONENT DESCRIPTION
Normal Brake Application
Slippery Road Operation
Wheel Brake Lock Operation
Secondary Brake Switch Operation
Automatic Emergency Brake Application
Parking Brake
BRAKE CIRCUIT COMPONENT SERVICE
DUAL CONTROLLER
Operation Of Brake Controller Components
Removal
Installation
Service
Disassembly
Cleaning and Inspection
Assembly
BENCH ADJUSTMENT
Equipment Required:
Adjustments
HYDRAULIC BRAKE CONTROLLER TROUBLESHOOTING
HYDRAULIC BRAKE ACCUMULATORS
Brake Accumulator Bleed Down Procedure
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Charging Procedure
DIFFERENTIAL PRESSURE MANIFOLD
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly and Initial Adjustment
Final Adjustment
PILOTED SINGLE CONTROLLER
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Bench Test
Equipment Needed:
Set-Up
Adjustment
DRY/SLIPPERY ROAD SOLENOID VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
BRAKE CIRCUIT CHECK OUT AND ADJUSTMENT PROCEDURE
BRAKE CIRCUIT COMPONENT LEAKAGE TEST
Accumulators
Dual Controller and Piloted Single Controller
Dry/Slippery Road Valve
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT
FRONT WHEEL SPEED DISC BRAKES
CARLISLE WHEEL SPEED DISC BRAKES
BRAKE CALIPERS
Lining Replacement
Brake Caliper Removal
Brake Caliper Installation
Brake Caliper Disassembly
Inspection
Brake Caliper Assembly
BRAKE CALIPER BENCH TEST
BRAKE BLEEDING PROCEDURE
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE
Front Brake Conditioning
Temporary Disconnect Procedures For Rear Brakes
Temporary Disconnect Procedures for Disabling Rear Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks
Temporary Disconnect Procedures for Disabling Rear Brakes For Model 830E HAULPAK® Trucks
SPECIAL TOOLS
ROCKWELL WHEEL SPEED FRONT DISC BRAKES
BRAKE CALIPER
BRAKE LINING
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE
TEMPORARY DISCONNECT PROCEDURES FOR REAR BRAKES
BRAKE BLEEDING PROCEDURES
REAR ARMATURE SPEED DISC BRAKES
CARLISLE ARMATURE SPEED REAR DISC BRAKES
BRAKE CALIPERS
Lining Replacement
Caliper Removal
Inspection
Installation
Disassembly of Brake Calipers
Inspection
Caliper Assembly
BRAKE CALIPER BENCH TEST
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE
General
Carlisle Armature Speed Disc Brakes Conditioning (Burnishing) Rear Brakes
BLEEDING PROCEDURE
TEMPORARY DISCONNECT PROCEDURES FOR DISABLING FRONT BRAKES
Temporary Disconnect Procedures for Disabling Front Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks
Temporary Disconnect Procedures for Disabling Front Brakes For Model 830E HAULPAK® Trucks
ROCKWELL ARMATURE SPEED REAR DISC BRAKES
REAR BRAKES
CALIPER, DISC AND PARKING BRAKE
FUNCTIONAL TEST OF PISTON ASSEMBLY
BRAKE LINING
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE
BLEEDING PROCEDURE
REAR DISC PARKING BRAKE
CARLISLE DISC PARKING BRAKE
PARKING BRAKE OPERATION
TRUCKS WITH ROCKWELL SERVICE BRAKES
Caliper Removal
Caliper Installation
TRUCKS WITH CARLISLE SERVICE BRAKES
Caliper Removal
Caliper Installation
Lining Replacement
Caliper Disassembly
Inspection
Caliper Assembly
BRAKE CALIPER BENCH TEST
PARKING BRAKE BLEEDING
CONDITIONING PROCEDURE FOR DISC PARKING BRAKE
500 HOUR SERVICE GUIDE FOR DISC PARKING BRAKE
ROCKWELL DISC PARKING BRAKE
CALIPER STYLE IDENTIFICATION
REMOVAL
INSTALLATION
PARKING BRAKE ADJUSTMENT (SCL 70)
PARKING BRAKE ADJUSTMENT (SCL15)
PARK BRAKE CALIPER DISASSEMBLY
CLEANING AND INSPECTION
PARK BRAKE CALIPER ASSEMBLY
PARK BRAKE LINING REPLACEMENT
PARK BRAKE BURNISH PROCEDURE
BRAKE BLEEDING PROCEDURE

SECTION K AIR SYSTEM INDEX
AIR SYSTEM OPERATION
AIR COMPONENT DESCRIPTION
Air Compressor
Air Starter Circuit (If Equipped*)
Air Dryer/Aftercooler
Air Dryer (If Equipped)
Aftercooler (If Equipped)
Check Valve
Main Air Tank
Safety Valve
Automatic/Manual Drain Valve
Air Governor
Radiator Pressure Regulating Valve (Detroit Diesel Engine Only)
90 psi (622 kPa) Air Regulating Valve For Contact Relays
Air System Lubricator (If Equipped)
Shop Air Quick Disconnect
AIR SYSTEM COMPONENT REPAIR
AIR COMPRESSOR SERVICE
AIR DRYER/AFTERCOOLER
SAFETY VALVE
Operating Test
AIR GOVERNOR
Disassembly
Cleaning and Inspection
Assembly
Adjustment
Leakage Tests
AUTOMATIC/MANUAL DRAIN VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
RADIATOR PRESSURE REGULATING VALVE (Detroit Diesel Engine Only)
Removal
Installation and Adjustment
Disassembly
Cleaning and Inspection
Assembly
AIR PRESSURE REGULATING VALVE FOR CONTACT RELAYS [90 psi (622 kPa)]
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Adjustment
AIR STARTER CIRCUIT (If Equipped)
AIR SYSTEM LUBRICATOR (If Equipped)
Service
Adjustment
AIR STARTER CIRCUIT
DUMP VALVE
AIR START SOLENOID VALVE
AIR STARTER
AIR STARTER COMPONENT REPAIR
AIR START SOLENOID VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Service
Assembly
DUMP VALVE
Removal
Installation
AIR STARTER
Removal
Installation
Disassembly Tips
Disassembly
Assembly
Test and Inspection Procedure
AIR STARTER LUBRICATOR
Removal
Installation
TROUBLESHOOTING CHART
THROTTLE TREADLE VALVE
COMPONENT DESCRIPTION
Treadle Valve
Service
COMPONENT REPAIR
Removal
Installation
Disassembly
Inspection
Assembly

SECTION L HYDRAULIC SYSTEM INDEX
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OPERATION
COMPONENT DESCRIPTION
High Pressure Filters
Hydraulic Pump
Hydraulic Tank
HYDRAULIC SYSTEM (With Trolley Assisted Option)
HYDRAULIC SYSTEM DESCRIPTION
HYDRAULIC SYSTEM COMPONENT REPAIR
HYDRAULIC PUMP
Removal
Installation
Pump Disassembly
Pump Assembly
Cartridge Disassembly
Inspection
Cartridge Assembly
TROUBLESHOOTING CHART
HYDRAULIC TANK
Filling Instructions
Removal
Installation
HYDRAULIC TANK STRAINER AND DIFFUSER
Removal
Inspect and Clean
Installation
HYDRAULIC SYSTEM FLUSHING PROCEDURE
STEERING CIRCUIT
STEERING CIRCUIT OPERATION
COMPONENT DESCRIPTION
Steering Control Valve
Unloader Valve
Operation
Bleeddown Manifold
Bleeddown Solenoid
Accumulators
High Pressure Filter
Flow Amplifier
FLOW AMPLIFIER SYSTEM OPERATION
No Steer
Steering Left
Steering Right
No Steer, External Shock Load
STEERING CONTROL VALVE
STEERING CONTROL VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Alternate Method for Installing Centering Springs
STEERING CIRCUIT COMPONENT REPAIR
UNLOADER VALVE
Removal
Installation and Adjustment
REBUILDING UNLOADER VALVE
Disassembly
Clean and Inspect
Assembly
BLEEDDOWN MANIFOLD
Removal
Adjusting Relief Valve
Testing and Adjustment
FLOW AMPLIFIER
Removal
Installation
Disassembly
Assembly
ACCUMULATORS
Removal
Installation
Cleaning and Inspection
Assembly
STEERING ACCUMULATOR CHARGING PROCEDURE
STEERING CYLINDERS
Disassembly
Assembly
STEERING CIRCUIT FILTER (OPTIONAL)
Removal
Installation
STEERING CIRCUIT TEST PROCEDURE
PRESSURE ADJUSTMENT PROCEDURE
COMPONENT LEAKAGE TEST
TROUBLESHOOTING CHART
HOIST CIRCUIT
HOIST CIRCUIT OPERATION
COMPONENT DESCRIPTION
Hydraulic Tank
Hydraulic Pump
High Pressure Filters
Hoist Valve
Hoist Pilot Valve
Hoist-up Limit Solenoid
Pilot Operated Check Valve
Hoist Valve Operation
Float Operation
Power Up Operation (Figure 7-4)
Hold Operation (Figure 7-5)
Power Down Operation (Figure 7-6)
Float Operation (Figure 7-7)
HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE
Removal
Installation
Disassembly
INLET SECTION
Disassembly
Cleaning and Inspection
Reassembly
SPOOL SECTION
Disassembly
Cleaning and Inspection
Reassembly
HOIST PILOT VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Reassembly
HOIST CYLINDERS
Removal
Installation
Disassembly
Cleaning and Inspection
ASSEMBLY OF QUILL AND CYLINDER
Quill Installation
Installation Of Check Balls And Plugs In Quill
Assembly of Cylinder
HIGH PRESSURE FILTERS
Removal
Installation
BODY UP LIMIT SOLENOID
PILOT OPERATED CHECK VALVE
CHECKING HOIST SYSTEM PRESSURE RELIEF VALVE

SECTION M OPTIONS AND SPECIAL TOOLS INDEX
FIRE CONTROL SYSTEM (M02002)
FIRE CONTROL SYSTEM (MANUAL) (02004)
ANSUL AUTOMATIC FIRE CONTROL SYSTEM (CHECKFIRE PNEUMATIC) (02002)
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 (02003)
LINCOLN AUTOMATIC LUBRICATION SYSTEM (M03001)
OPERATION
Operation
Components
Description of Components
GENERAL INSTRUCTIONS
Lubricant Required for System
Initial Reservoir Fill
System Priming
SYSTEM CHECKOUT
24 VDC SOLID STATE TIMER CHECK
INJECTORS (SL-1 SERIES “H”)
TROUBLESHOOTING CHART
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM (M04002)
SYSTEM ADJUSTMENT
PUMP
BLOWER DRIVE MOTOR
BLOWER BEARING REPAIR
AIR CLEANER
WIGGINS QUICK FILL FUEL SYSTEM (M05002)
TANK BREATHER VALVE
FUEL RECEIVER
FAN DRIVE CLUTCH (M06001)
GENERAL DESCRIPTION
MAINENANCE
TROUBLESHOOTING
FIELD CHECK DIAGNOSIS
THERMAL SENSOR AND SOLENOID VALVE
TROUBLESHOOTING CHART
COMPONENTS PARTS LIST
DISASSEMBLY INSTRUCTIONS
REASSEMBLY OF THE FAN CLUTCH
INSPECTION OF PARTS
REBUILD TOOLS
ENGINE COOLANT HEATER (M07001)
HEATING ELEMENT
THERMOSTAT
ENGINE OIL HEATERS (M07003)
TROUBLESHOOTING
HEATING ELEMENT
ENGINE COOLANT & OIL HEATERS, 440 VOLT (M07004)
TROUBLESHOOTING
COOLANT HEATER ELEMENT
OIL HEATER ELEMENT
THERMOSTAT
SPECIAL TOOLS (M08008)
AIR CONDITIONING SYSTEM (M09003)
PRINCIPLES OF REFRIGERATION
Refrigeration – The Act Of Cooling
The Refrigeration Cycle
AIR CONDITIONER SYSTEM COMPONENTS
Compressor (Refrigerant Pump)
Service Valves
Condenser
Filter Receiver-drier
Fusible Pressure Relief Plug
Thermostatic Expansion Valve
Evaporator
Superheat
SYSTEM SERVICING
R-12 Containers
TROUBLESHOOTING
PRE-DIAGNOSIS CHECKS
PREPARING FOR DIAGNOSIS
PRELIMINARY STEPS
DIAGNOSIS OF GAUGE READINGS & SYSTEM PERFORMANCE
TROUBLESHOOTING CHART
HEATER/AIR CONDITIONER SERVICE
COMPONENT SERVICE
Refrigerant Discharge
COMPRESSOR
Cylinder Head (Gasket) Removal
Installation
Compressor Removal
Installation
CONDENSER
Removal
Installation
RECEIVER/DRYER
Removal
Installation
EVAPORATOR COIL, THERMOSTAT SWITCH, AND EXPANSION VALVE
EXPANSION VALVE
Removal
Installation
BLOWER MOTOR ASSEMBLY
Removal
Installation
Blower Disassembly
Blower Assembly
AFTERCOOLER OPERATION AND REPAIR
OPERATION
MAINTENANCE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
AIR DRYER (AEROFINER III) (M10003)
AIR DRYER
Service
Indications To Change Desiccant
Removal
Installation
Disassembly
Assembly
CHECK VALVE
Removal
Installation
PURGE VALVE & HEATER
Removal
Inspection
Installation
SALEM AFTERCOOLER (AIR DRYER) (M10004)
AFTERCOOLER/AIR DRYER
Removal
Disassembly
Cleaning and Inspection
Reassembly and Installation
OPTIONAL OPERATOR SEAT (M14001)
SEAT
Removal
Installation
Disassembly
Assembly
Air Suspension Cam Adjustment
SEAT MAINTENANCE AND REPAIR
Headrest
Backrest
Armrests
Seat Cushion
Seat Frame
Slides
Suspension
TDI SINGLE STAGE AIR STARTER (M15001)
Disassebly
PARTS INSPECTION (Refer to Figure 15-2 for reference to parts)
Assembly
TDI TWO-STAGE AIR STARTER
AIR STARTER
Removal
Installation
Description of Basic Groups
Disassembly
Cleaning and Inspection
Assembly
STARTER
Removal
Installation
Disassembly
Cleaning
Parts Inspection
AUTOMATIC TRIP VALVE
Disassembly
Reassembly
Operation Check
TDI TWO-STAGE AIR STARTER TROUBLESHOOTING GUIDE
INGERSOLL-RAND TURBINE POWERED STARTER (M15002)
MAINTENANCE
Removal
Installation
Disassembly Tips
Disassembly – Housing Exhaust Cover, Motor Assembly, and Motor Housing
Disassembly – Drive Housing
Assembly Tips
Lubrication
Assembly – Gear Case and Drive Housing
Assembly – Intermediate Gear Case, Motor Housing, Motor Assembly, and Housing Exhaust Cover
TEST AND INSPECTION PROCEDURE
TROUBLESHOOTING CHART
24 VDC ELECTRIC START SYSTEM (M17001)
OPERATION
CRANKING MOTOR
Removal
Installation
CRANKING MOTOR TROUBLESHOOTING
Preliminary Inspection
No-Load Test
Interpreting Results of Tests
Disassembly
Cleaning and Inspection
Armature Servicing
Field Coil Checks
Field Coil Removal
Solenoid Checks
Test
Assembly
Pinion Clearance
Magnetic Switch
Removal
Installation
Coil Test
ELECTRIC START SYSTEM WIRING DIAGRAMS
HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS) (M20001C1)
TROUBLESHOOTING THE HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS)
ERROR CODES
GENERAL INFORMATION
TIPS FOR OPERATION
DECK MOUNTED LIGHTS
OPERATION AND FUNCTIONS
DISPLAY LOGIC
METRIC/SHORT TON SELECTION
DATA STORAGE LOGIC
DATA PRINT OUT
CLEAR MEMORY
SETTING THE TIME OF DAY
CALIBRATING THE PAYLOAD METER
To perform calibration:
DIMMING THE PAYLOAD METER DISPLAY
ERROR CODES
SERVICING THE PAYLOAD METER
Payload Meter Removal
Payload Meter Installation
REPLACING PRINTER PAPER
Replacing Paper
Troubleshooting Paper Printer
REPLACEMENT OF PRINTER MODULE
Printer Module Removal
Printer Module Installation
BATTERY (P/N EC2453)
Removal
Installation
PRESSURE SENSOR
To Perform A Sensor Check:
Removal
Installation
INCLINOMETER
Removal
Installation
RELAYS AND DATA STORAGE TRIGGER MODULE (DSTM)
PAYLOAD METER SELF TEST FUNCTIONS
CHECK OUT PROCEDURE
Deck Mounted Lights
Pressure Sensor Location
Error Codes
Data storage trigger module
Inclinometer
Body Up Switch
ON-BOARD WEIGHING SYSTEM SCHEMATIC
ON-BOARD WEIGHING SYSTEM EXPANDED MEMORY BOX (M20001C3)
DOWNLOAD
ANALYSIS
Tips For Operation
GETTING STARTED
Installing The Software
INITIAL START UP OF THE EXPANDED MEMORY BOX
COMMON PROCEDURES
DOWNLOAD PROGRAM
Payload Box
Download from Box
Set Date and Time
Clear Box Data
SPECIAL
Set Max Loads
Clear Meter
Box Info
Set Truck Number
View Data in Box
Set Comm Port
HELP
ANALYSIS PROGRAM
ANALYSIS
Data Tables
Graphics
Print Report
SETUP MENU
PRINTER CHART
HELP MENU
PAYLOAD DATA
SERVICE
Removal
Installation
Disassembly
Battery Replacement
Assembly
Wire Connections
TROUBLESHOOTING EXPANDED MEMORY BOX
DETROIT DIESEL ELECTRONIC ENGINE CONTROLS ABBREVIATIONS
DDEC II ELECTRONIC ENGINE CONTROL (M21001)
DDEC III ELECTRONIC ENGINE CONTROL (M21002)

SECTION N OPERATOR’S CAB INDEX
TRUCK CAB
TRUCK CAB
Removal
Installation
DOOR WINDOW SERVICE
Removal
Installation
Disassembly
Assembly
CAB DOOR
Removal
Installation
Door Adjustment
Door Latch
Removal
Installation
Disassembly
Assembly
WINDSHIELD AND REAR WINDOW SERVICE
Removal
Installation
CAB COMPONENTS
WINDSHIELD WIPER – AIR OPERATED
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
WIPER CONTROL VALVE
Removal
Installation
ELECTRIC WINDSHIELD WIPER
Removal
Installation
WINDSHIELD WASHER
Operation
Service
AIR HORN
OPERATOR COMFORT
OPERATOR SEAT
Adjustment
Removal
Installation
Disassembly
Inspection
Assembly
HEATER
WATER CONTROL VALVE
BLOWER AND HEATER CORE
Removal
Installation
Disassembly
Assembly
HEATER COVER
Installation
FILTER
Service
OPERATOR CONTROLS
STEERING COLUMN
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
Cleaning and Inspection
Assembly
THROTTLE PEDAL (1, Figure 5-9)
BRAKE PEDAL (2, Figure 5-9)
DIMMER SWITCH (3, Figure 5-9)
DYNAMIC RETARDING PEDAL (4, Figure 5-9)
HOIST CONTROL VALVE (5, Figure 5-9)
OPERATOR CAB CENTER CONSOLE (6-11, Figure 5-9)
Selector Switch (6)
Engine Shutdown Switch (7)
Engine Idle Switch (8) (Not Functional W/Statex III & Fuel Enhancement)
12vdc Power Supply (9)
Computer Diagnostic Port (10)
Data Store Switch (11)
INSTRUMENT PANEL
INSTRUMENT PANEL
INSTRUMENTS AND INDICATORS
(1) KEY SWITCH
(2) ENGINE SHUTDOWN (OPTIONAL)
(3) WINDSHIELD WIPER/WASHER SWITCH
(4) LIGHT SWITCH
(5) ENGINE STARTING AID (OPTIONAL)
(6) LADDER LIGHT SWITCH
(7) MANUAL BACKUP LIGHT SWITCH
(8) FOG LIGHTS (OPTIONAL)
(9) HIGH-MOUNTED HEADLIGHTS (OPTIONAL)
(10) PANEL LIGHT DIMMER
(11) WATER TEMPERATURE GAUGE
(12) ENGINE OIL PRESSURE GAUGE
(13) AIR PRESSURE GAUGE
(14) SPEEDOMETER
(15) LEFT TURN SIGNAL INDICATOR
(16) HIGH BEAM INDICATOR
(17) RIGHT TURN SIGNAL INDICATOR
(18) VOLTMETER
(19) WARNING DECAL
(20) BLANK
(21) TACHOMETER
CAUTION INDICATOR LIGHTS
(22) DYNAMIC RETARDING
(23) BODY UP
(24) SERVICE BRAKE
(25) PARKING BRAKE
(26) ACCUMULATOR BOOSTER (OPTIONAL)
(27) MANUAL BACK UP LIGHT
(28) LOW FUEL (OPTIONAL)
(29) HIGH PRESSURE FILTER (Optional)
(30) ENGINE CHECK MAIN (“DDEC” Electronic Engine Controls or Cummins Engines Equipped With Centry™ Fuel Control)
(31) Engine Check Second (Used Only with “DDEC II” – Controlled Engine)
(32) Battery Check (“DDEC” – Controlled Engines Only)
(33) CIRCUIT BREAKER TRIPPED
(34) PARKING BRAKE CONTROL
(35) SECONDARY BRAKE CONTROL
(36) DRY ROAD/SLIPPERY ROAD SWITCH
(37) WHEEL BRAKE LOCK
RETARD SPEED CONTROLS (RSC) (38, 39, & 40, FIGURE 5-11)
(38) RETARD SPEED CONTROL INDICATOR
(39) RETARD SPEED CONTROL (RSC) SWITCH
(40) RSC ADJUST DIAL
(41) OVERRIDE PUSHBUTTON
(42) WARNING DECAL
(43) LOW STEERING PRESSURE
(44) LOW ACCUMULATOR PRECHARGE
(45) HIGH HYDRAULIC OIL TEMPERATURE (OPTIONAL)
(46) LOW HYDRAULIC TANK LEVEL (OPTIONAL)
(47) HIGH COOLANT TEMPERATURE (Not Used With “Flight/Engine Saver” or “DDEC”- Controlled Engine)
(48) LOW COOLANT LEVEL (Not Used With “DDEC” – Engine)
(49) LOW OIL PRESSURE (Not Used With “Engine Saver” or “DDEC” – Engine)
(50) LOW OIL LEVEL (OPTIONAL)
(51) Used ONLY With Electronic-Controlled Engine Options
ENGINE MONITOR (Used for “Flight/Engine Saver” Option)
ENGINE MONITOR MAIN – (“DDEC”)
(52) CRANKCASE PRESSURE WARNING LIGHT (Used Only for Detroit Diesel Engine Without DDEC Controls)
(53) LOW BRAKE PRESSURE
(54) ENGINE MONITOR SECOND (Used Only With “DDEC II” Electronic- Controlled Engine Option)
(55) ELECTRIC SYSTEM FAULT
(56) MOTOR BLOWER OFF
(57) HIGH MOTOR TEMPERATURE (OPTIONAL)
(58) BLANK
(59) LAMP TEST and Cummins Centry™ Diagnostic Test Switch (if equipped)
(60) HEATER TEMPERATURE CONTROL LEVER
(61) DEFROSTER/HEAT CONTROL LEVER
(62) OUTSIDE/INSIDE AIR CONTROL LEVER
(63) AIR CONDITIONER CONTROL (OPTIONAL)
(64) FAN CONTROL KNOB
(65) AIR CLEANER SERVICE VACUUM GAUGE
(66) FUEL LEVEL GAUGE (OPTIONAL)
(67) HOURMETER
(68) OVERSPEED ALARM HORN (OPTIONAL)
(69) CIRCUIT BREAKERS
CENTRY™ FUEL SYSTEM DIAGNOSTICS – CUMMINS ENGINE ONLY –
DETERMINING “FAULT” CODES
EXITING THE DIAGNOSTICS MODE

SECTION P LUBRICATION AND SERVICE INDEX
LUBRICATION AND SERVICE
HYDRAULIC TANK SERVICE
Adding Oil
LUBRICATION CHART
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS
50 HOUR LUBRICATION AND MAINTENANCE CHECKS
100 HOUR LUBRICATION AND MAINTENANCE CHECKS
250 HOUR LUBRICATION AND MAINTENANCE CHECKS
500 HOUR LUBRICATION AND MAINTENANCE CHECKS
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS
5000 HOURS LUBRICATION AND MAINTENANCE CHECKS
10000 HOURS LUBRICATION AND MAINTENANCE CHECKS
MOTORIZED WHEEL MAINTENANCE SCHEDULE

SECTION Q ALPHABETICAL INDEX

SECTION R SYSTEM SCHEMATICS INDEX
AIR SYSTEM SCHEMATIC HA195
AIR SYSTEM SCHEMATIC HA198
BRAKE SYSTEM HYDRAULIC SCHEMATIC HH313
HYDRAULIC SYSTEM SCHEMATIC HUSCO VALVE HH309
Sheet 1
Sheet 2
Sheet 3
RETARD CONTROL PANEL FOR STATEX III HE378
ACCEL INTERFACE PANEL FOR STATEX III HE379
STATEX III POWER AND EXCITATION SCHEMATIC HE376
Sheet 1
Sheet 2
Sheet 3
ELECTRICAL SCHEMATIC HE400
Sheet 1
Sheet 2
Sheet 3
Sheet 4
Sheet 5
Sheet 6
Sheet 7
Sheet 8
Sheet 9
Sheet 10
Sheet 11
Sheet 12
Sheet 13
Sheet 14
Sheet 15

–