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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30299 – A30309 & A30311) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30299 – A30309 & A30311
- PUBLICATION NUMBER:CEBM014700
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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30299 – A30309 & A30311) KOMATSU 730E
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30299 – A30309 & A30311) KOMATSU 730E – PDF DOWNLOAD:
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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30299 – A30309 & A30311) KOMATSU 730E
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 730E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30299 – A30309 & A30311) KOMATSU 730E
MAIN MENU.................................................................... 0 COVER........................................................................ 1 FOREWARD..................................................................... 4 CONTENTS..................................................................... 6 A. GENERAL INFORMATION....................................................... 8 TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS............................. 10 GENERAL SAFETY AND TRUCK OPERATION....................................... 14 WARNINGS AND CAUTIONS.................................................... 40 CHARTS AND TABLES........................................................ 48 STORAGE PROCEDURES....................................................... 54 B. STRUCTURES................................................................ 72 STRUCTURAL COMPONENTS.................................................... 74 GRILLE AND HOOD...................................................... 74 LADDERS.............................................................. 75 DECKS................................................................ 75 RIGHT DECK AND COMPONENTS........................................ 75 LEFT DECK........................................................ 75 DUMP BODY................................................................ 78 INSTALLATION......................................................... 78 REMOVAL.............................................................. 78 BODY PADS............................................................ 79 BODY GUIDE........................................................... 80 BODY SLING........................................................... 80 BODY POSITION INDICATOR.............................................. 80 ROCK EJECTORS........................................................ 81 HOIST LIMIT SWITCHES................................................. 81 FUEL TANK................................................................ 82 REMOVAL.............................................................. 82 INSTALLATION......................................................... 83 CLEANING............................................................. 83 VENT................................................................. 83 FUEL GAUGE SENDER.................................................... 83 C. ENGINE, FUEL, COOLING, AND AIR CLEANER.................................... 84 POWER MODULE............................................................. 86 REMOVAL.............................................................. 86 INSTALLATION......................................................... 90 COOLING SYSTEM........................................................... 92 RADIATOR............................................................. 92 REMOVAL.......................................................... 92 SERVICE.......................................................... 93 INSTALLATION..................................................... 93 RADIATOR FILL PROCEDURE.......................................... 94 COOLING SYSTEM TROUBLESHOOTING................................... 95 POWER TRAIN.............................................................. 96 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE........................ 96 REMOVAL.......................................................... 96 ENGINE / ALTERNATOR MATING........................................... 98 ALTERNATOR MEASUREMENT........................................... 98 ENGINE END PLAY MEASUREMENT...................................... 99 DETERMINING SHIM REQUIREMENTS.................................... 99 INSTALLATION.....................................................100 ENGINE...............................................................102 REMOVAL..........................................................102 INSTALLATION.....................................................102 AIR CLEANERS.............................................................104 FILTER ELEMENT REPLACEMENT...........................................104 MAIN FILTER ELEMENT CLEANING.........................................106 PRECLEANER SECTION...................................................107 D. ELECTRIC SYSTEM (24 VDC, NON-PROPULSION)..................................112 24 VDC ELECTRIC SUPPLY SYSTEM............................................114 ELECTRICAL SYSTEM DESCRIPTION........................................114 BATTERY - MAINTENANCE AND SERVICE....................................114 ELECTRIC START SYSTEM................................................116 OPERATION........................................................116 REMOVAL......................................................116 INSTALLATION.................................................116 CRANKING MOTOR TROUBLESHOOTING...................................117 DISASSEMBLY......................................................118 SOLENOID CHECKS..................................................121 ASSEMBLY.........................................................122 ENGINE PRELUB STARTER SYSTEM.........................................125 OPERATION........................................................125 TROUBLESHOOTING..................................................127 24 VDC ELECTRICAL SYSTEM COMPONENTS......................................130 PASSENGER SEAT BASE COMPARTMENT......................................130 TAIL LIGHT RESISTOR DIODE ASSEMBLIES.............................130 5 MINUTE IDLE TIMER COMPONENTS...................................132 ALARM INDICATING DEVICE (A.I.D. SYSTEM)..........................133 BODY UP SWITCH.......................................................136 HOIST LIMIT SWITCH...................................................136 24 VDC RELAY AND DIODE BOARDS........................................137 DESCRIPTION......................................................137 RELAY BOARD 1 (TURN SIGNAL)......................................139 RELAY BOARD 2 (PAYLOAD METER)....................................139 RELAY BOARD 3 (STOP LIGHTS)......................................140 RELAY BOARD 4 (PARKING BRAKE)....................................140 RELAY BOARD 5 (HEADLIGHTS).......................................140 RELAY BOARD 6 (AUXILIARY PANEL)..................................141 DIODE BOARD 1....................................................142 CIRCUIT BREAKER CHART............................................143 E. ELECTRIC PROPULSION AND CONTROL...........................................144 ELECTRICAL PROPULSION COMPONENTS.........................................146 GENERAL SYSTEM DESCRIPTION...........................................146 CONTROL SYSTEM.......................................................146 FL275 PANEL..........................................................148 COMPUTER DESCRIPTION.............................................150 SOFTWARE.........................................................150 2-DIGIT DISPLAY PANEL................................................153 EVENTS...........................................................153 FRAMES...........................................................154 WINDOWS..........................................................154 EVENT CODE DESCRIPTIONS (TABLE I)............................156 SUBCODE DESCRIPTIONS (TABLE II)..............................163 PORTABLE TEST UNIT (PTU).............................................166 DESCRIPTION......................................................166 SOFTWARE INSTALLATION PREPARATION................................167 THE MAIN MENU................................................169 PTU SOFTWARE MENU TREE.......................................170 CONFIGURATION (CFG) FILE CONVERSION..........................171 STATEX CONFIGURATION FILES.......................................175 PROGRAMMING THE TRUCK............................................186 PTU HOOKUP...................................................186 DOWNLOAD CONFIGURATION FILES.................................188 EVENT DATA.......................................................190 STATISTICAL DATA.................................................193 STATISTICAL DATA CODES - COUNTERS (TABLE III)................194 STATISTICAL DATA CODES - PROFILES (TABLE IV).................199 TRUCK SPECIFIC INFORMATION.......................................203 TEMPORARY TRUCK SETTINGS.........................................204 MISCELLANEOUS SOFTWARE FEATURES..................................205 SAVING DATA..................................................205 PTU ABBREVIATIONS............................................206 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS...........................207 ALTERNATOR...........................................................207 ELECTRIC WHEEL MOTORS................................................207 RETARDING GRIDS......................................................207 ELECTRONIC ACCELERATOR AND RETARD CONTROL............................207 COOLING BLOWER WARNING SYSTEM........................................209 ELECTRICAL CONTROL CABINET...........................................210 STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS...................215 ELECTRICAL CHECKOUT PROCEDURE............................................218 G. DRIVE AXLE, SPINDLES AND WHEELS...........................................270 TIRES AND RIMS...........................................................272 FRONT TIRES AND RIMS.................................................272 REMOVAL..........................................................272 INSTALLATION.....................................................273 REAR TIRES AND RIMS..................................................274 REMOVAL..........................................................274 INSTALLATION.....................................................275 RIM..................................................................276 TIRE REMOVAL.....................................................276 TIRE INSTALLATION................................................277 FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)............................280 WHEEL HUB AND SPINDLE ASSEMBLY.......................................280 REMOVAL.......................................................... 0 INSTALLATION.....................................................282 DISASSEMBLY......................................................282 CLEANING AND INSPECTION..........................................283 ASSEMBLY.........................................................283 WHEEL BEARING ADJUSTMENT (TIRE REMOVED)..........................285 WHEEL BEARING ADJUSTMENT (TIRE MOUNTED)..........................286 STEERING CYLINDERS AND TIE ROD.......................................288 REMOVAL..........................................................289 INSTALLATION.....................................................290 BEARING REPLACEMENT..............................................290 TOE-IN ADJUSTMENT....................................................291 REAR AXLE HOUSING ATTACHMENT (G04010)....................................292 PIVOT PIN............................................................292 REMOVAL..........................................................292 INSTALLATION.....................................................292 DISASSEMBLY......................................................293 ASSEMBLY.........................................................293 ANTI-SWAY BAR........................................................295 REMOVAL..........................................................295 INSTALLATION.....................................................295 DISASSEMBLY......................................................295 CLEANING AND INSPECTION..........................................295 ASSEMBLY.........................................................295 REAR AXLE HOUSING (G05004)...............................................296 REAR AXLE HOUSING....................................................296 REMOVAL..........................................................296 INSTALLATION.....................................................296 WHEEL MOTOR..........................................................296 REMOVAL..........................................................296 CLEANING AND INSPECTION..........................................297 INSTALLATION.....................................................297 H. HYDRAIR II SUSPENSIONS....................................................298 FRONT SUSPENSION.........................................................300 REMOVAL..............................................................300 INSTALLATION.........................................................301 DISASSEMBLY......................................................304 ASSEMBLY (BEARING RETAINER ONLY).................................306 ASSEMBLY (COMPLETE)..............................................306 SUSPENSION PRESSURE TEST.............................................307 REAR SUSPENSION..........................................................308 REMOVAL..............................................................309 INSTALLATION.........................................................311 DISASSEMBLY...................................................... 0 ASSEMBLY......................................................... 0 SUSPENSION PRESSURE TEST.............................................314 OILING AND CHARGING PROCEDURES...........................................316 GENERAL..............................................................316 EQUIPMENT LIST.......................................................316 FRONT SUSPENSION.....................................................318 FRONT SUSPENSION OILING..........................................318 FRONT SUSPENSION NITROGEN CHARGING...............................319 REAR SUSPENSION......................................................320 REAR SUSPENSION OILING...........................................320 REAR SUSPENSION NITROGEN CHARGING................................321 OIL AND NITROGEN SPECIFICATIONS..........................................323 J. BRAKE CIRCUIT.............................................................324 BRAKE CIRCUIT............................................................326 SERVICE BRAKE CIRCUIT OPERATION......................................326 SECONDARY BRAKING AND AUTOMATIC APPLY................................328 PARKING BRAKE CIRCUIT................................................328 BRAKE LOCK CIRCUIT...................................................329 WARNING CIRCUIT......................................................329 BRAKE VALVE CUT-AWAY.................................................330 BRAKE CIRCUIT COMPONENT SERVICE..........................................332 BRAKE VALVE..........................................................332 REMOVAL..........................................................332 INSTALLATION.....................................................334 DISASSEMBLY......................................................336 CLEANING AND INSPECTION..........................................338 ASSEMBLY.........................................................342 BENCH TEST AND ADJUSTMENT........................................342 INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE.....346 INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE........348 HYDRAULIC BRAKE ACCUMULATORS.........................................349 REMOVAL..........................................................349 INSTALLATION.....................................................349 DISASSEMBLY......................................................349 CLEANING AND INSPECTION..........................................350 ASSEMBLY.........................................................351 CHARGING PROCEDURE...............................................352 BRAKE CIRCUIT CHECKOUT PROCEDURE.........................................354 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................360 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET....................364 FRONT BRAKES (ROCKWELL)..................................................366 BRAKE CALIPER........................................................366 BRAKE LINING.........................................................370 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE........................371 BRAKE BLEEDING PROCEDURE.............................................372 REAR BRAKES (ROCKWELL)...................................................374 BRAKE CALIPER, DISC AND PARKING BRAKE................................374 CALIPER PISTON ASSEMBLY..............................................379 BENCH TEST...........................................................380 BRAKE LINING.........................................................386 BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE.........................389 BRAKE BLEEDING PROCEDURE.............................................391 PARKING BRAKE (ROCKWELL).................................................392 CALIPER..............................................................392 REMOVAL..........................................................392 INSTALLATION.....................................................393 PARKING BRAKE ADJUSTMENT (SCL 70)................................393 PARKING BRAKE ADJUSTMENT.................................................393 PARK BRAKE CALIPER DISASSEMBLY.......................................395 CLEANING AN INSPECTION...............................................395 PARK BRAKE CALIPER ASSEMBLY..........................................396 PARK BRAKE LINING........................................................397 REPLACEMENT..........................................................397 CONDITIONING (BURNISHING PROCEDURE)..................................397 BRAKE BLEEDING PROCEDURE.................................................397 L. HYDRAULIC SYSTEM..........................................................398 HYDRAULIC SYSTEM.........................................................400 HOIST CIRCUIT OPERATION..............................................400 STEERING CIRCUIT OPERATION...........................................402 HYDRAULIC COMPONENT REPAIR...............................................406 HOIST PUMP...........................................................406 REMOVAL..........................................................406 INSTALLATION.....................................................407 DISASSEMBLY......................................................408 INSPECTION.......................................................410 ASSEMBLY.........................................................411 TROUBLESHOOTING GUIDE............................................415 HYDRAULIC TANK...........................................................416 FILLING INSTRUCTIONS.................................................416 REMOVAL..............................................................417 INSTALLATION.........................................................417 STRAINER AND DIFFUSER................................................417 STEERING CIRCUIT.........................................................420 STEERING CIRCUIT OPERATION...........................................420 COMPONENT DESCRIPTION................................................421 STEERING CONTROL VALVE...........................................421 UNLOADER VALVE...................................................421 BLEED DOWN MANIFOLD VALVE........................................422 FLOW AMPLIFIER...................................................426 STEERING PUMP....................................................435 ACCUMULATORS.....................................................435 STEERING CONTROL VALVE...............................................436 REMOVAL..........................................................436 INSTALLATION.....................................................436 REBUILD PROCEDURE................................................437 DISASSEMBLY..................................................437 CLEANING AND INSPECTION......................................438 ASSEMBLY.....................................................440 STEERING PUMP....................................................443 REMOVAL......................................................443 INSTALLATION.................................................443 DISASSEMBLY..................................................445 INSPECTION...................................................445 ASSEMBLY.....................................................445 STEERING CIRCUIT COMPONENT REPAIR....................................448 BLEEDDOWN MANIFOLD VALVE.........................................448 STEERING ACCUMULATORS............................................449 STEERING ACCUMULATORS CHARGING PROCEDURE.........................454 FLOW AMPLIFIER...................................................458 STEERING CYLINDERS...............................................463 HOIST CIRCUIT........................................................470 HOIST CIRCUIT OPERATION..........................................470 COMPONENT DESCRIPTION............................................471 HOIST CIRCUIT COMPONENT REPAIR.......................................484 HOIST VALVE......................................................484 HOIST PILOT VALVE................................................492 HOIST-UP LIMIT SOLENOID VALVE....................................495 HOIST CYLINDERS..................................................495 HYDRAULIC SYSTEM FILTERS.............................................504 HOIST CIRCUIT FILTER.............................................504 STEERING CIRCUIT FILTER..........................................506 HYDRAULIC CHECKOUT PROCEDURES........................................510 INITIAL START UP AND FLUSHING....................................511 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE....514 COMPONENT CHECKOUT AND ADJUSTMENT................................512 MANIFOLD REASSEMBLY..........................................515 OIL CLEANLINESS CHECK........................................516 COUNTERBALANCE VALVE ADJUSTMENT..............................515 DISABLED TRUCK DUMPING PROCEDURE.................................517 TROUBLESHOOTING CHARTS...........................................518 M. OPTIONS AND SPECIAL TOOLS.................................................526 FIRE CONTROL SYSTEMS.....................................................528 ANSUL FIRE CONTROL PNEUMATIC SYSTEM..................................528 ANSUL FIRE CONTROL ELECTRIC SYSTEM...................................534 ANSUL FIRE CONTROL SYSTEM MANUAL.....................................544 OPERATION........................................................544 INSPECTION AND MAINTENANCE.......................................544 RECHARGING PROCEDURES............................................545 WIGGINS QUICK FILL FUEL SYSTEM...........................................546 TANK BREATHER VALVE..................................................547 FUEL RECEIVER........................................................546 FAN DRIVE CLUTCH - HYDRAULIC ACTUATED....................................550 GENERAL DESCRIPTION..................................................550 MAINTENANCE..........................................................553 TROUBLESHOOTING......................................................555 FIELD CHECK DIAGNOSIS................................................556 THERMAL SENSOR AND SOLENOID VALVE................................557 TROUBLESHOOTING CHART................................................560 DISASSEMBLY..........................................................564 REASSEMBLY...........................................................571 INSPECTION OF PARTS..................................................582 REBUILD TOOLS........................................................587 ENGINE COOLANT HEATER SYSTEM - HOT START - 220 VOLT......................588 HEATING ELEMENT......................................................588 THERMOSTAT...........................................................589 ENGINE OIL HEATERS - HOT START - 220 VOLT................................590 TROUBLESHOOTING...................................................... 0 HEATING ELEMENT......................................................590 ENGINE AND COOLANT HEATERS - 440 VOLT....................................592 TROUBLESHOOTING......................................................593 COOLANT HEATING ELEMENT..............................................594 OIL HEATING ELEMENT..................................................595 SPECIAL TOOL GROUP.......................................................598 HEATER / AIR CONDITIONING SYSTEM.........................................606 ENVIRONMENTAL IMPACT.................................................606 OPERATOR CAB CONDITIONING............................................607 PRINCIPLES OF REFRIGERATION..........................................607 MAJOR SYSTEM COMPONENTS..............................................609 SYSTEM SERVICING.....................................................613 EVACUATING THE SYSTEM................................................630 SYSTEM TROUBLESHOOTING...............................................632 24 VDC ELECTRIC SUPPLY SYSTEM............................................642 ELECTRICAL SYSTEM DESCRIPTION........................................642 BATTERY - MAINTENANCE AND SERVICE....................................642 BATTERY CHARGING SYSTEM..............................................644 GENERAL DESCRIPTION..............................................644 TROUBLESHOOTING PROCEDURES.......................................644 NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL...............................652 DIMENSIONS...........................................................653 SPECIFICATIONS.......................................................654 SERVICE PARTS LIST...................................................655 EXPLODED VIEW........................................................656 ON VEHICLE TEST......................................................657 BENCH TEST...........................................................659 STATIC TESTS.........................................................660 ALTERNATOR DISASSEMBLY...............................................663 ALTERNATOR ASSEMBLY..................................................668 SERVICE TOOL INSTRUCTIONS............................................677 FUEL - WATER SEPARATOR...................................................680 INSTALLATION.........................................................680 OPERATION............................................................680 FILTER SERVICE.......................................................681 PAYLOAD METER III........................................................682 OPERATION SECTION....................................................685 INTRODUCTION.........................................................685 DATA SUMMARY.........................................................685 DATA GATHERING.......................................................685 COMPONENT DESCRIPTION................................................686 SYSTEM DIAGRAM...................................................686 SUSPENSION PRESSURE SENSORS......................................686 INCLINOMETER.....................................................686 OPERATOR DISPLAY.................................................686 OPERATOR SWITCH..................................................687 SPEED INPUT......................................................687 BODY-UP SWITCH...................................................687 BRAKE LOCK SWITCH................................................687 PAYLOAD METER....................................................687 COMMUNICATIONS PORT..............................................687 KEYSWITCH INPUT..................................................688 PAYLOAD METER POWER..............................................688 LOAD LIGHTS......................................................688 WIRING AND TERMINATION...........................................689 TCI OUTPUTS......................................................689 OPERATOR'S DISPLAY AND SWITCH........................................690 READING THE SPEEDOMETER..........................................690 READING THE LOAD DISPLAY.........................................690 USING THE OPERATOR ID............................................690 USING THE LOAD AND TON COUNTER...................................690 TOTAL TON COUNTER............................................682 TOTAL LOAD COUNTER...........................................691 CLEARING THE COUNTERS........................................691 VIEWING LIVE SENSOR DATA.........................................691 OTHER DISPLAY MESSAGES...........................................691 PAYLOAD OPERATION AND CALCULATION....................................692 DESCRIPTION OF HAUL CYCLE STATES.................................692 STAGES OF A TYPICAL HAUL CYCLE...............................692 HAUL CYCLE DESCRIPTION.......................................692 LOAD CALCULATION.................................................693 CARRY BACK.......................................................693 MEASUREMENT ACCURACY.............................................693 SOURCES FOR PAYLOAD ERROR........................................693 PAYLOAD ERROR................................................693 LOADING CONDITIONS...........................................694 PRESSURE SENSORS.............................................694 SWINGLOADS...................................................694 SPEED AND DISTANCE...........................................694 HAUL CYCLE DATA......................................................695 HAUL CYCLE DATA..................................................695 HAUL CYCLE WARNING FLAGS.........................................696 ALARM RECORDS....................................................697 FRAME TORQUE DATA................................................697 SPRUNG WEIGHT DATA...............................................698 MAXIMUM SPEED DATA...............................................698 PC SOFTWARE OVERVIEW.................................................698 PC OVERVIEW......................................................698 SYSTEM CONFIGURATION.............................................698 INSTALLING THE PAYLOAD METER III SOFTWARE........................698 DOWNLOADING DATA.....................................................699 PLM III SYSTEM CONFIGURATION.........................................700 STARTING COMMUNICATIONS..........................................700 DISPLAYED PAYLOAD UNITS......................................700 TIME UNITS...................................................700 CONNECTION MENU..................................................700 CONNECTING TO THE PAYLOAD METER..................................701 CONFIGURE THE PAYLOAD METER......................................701 SETTING THE DATE AND TIME....................................701 SETTING THE TRUCK TYPE.......................................702 SETTING THE GAUGE DISPLAY UNITS..............................702 SETTING THE FRAME SERIAL NUMBER..............................702 SETTING THE TRUCK NUMBER.....................................702 SETTING THE KOMATSU DISTRIBUTOR..............................702 SETTING THE KOMATSU CUSTOMER.................................702 CLEAN TRUCK TARE.................................................703 INCLINOMETER CALIBRATION.........................................703 DATA ANALYSIS........................................................704 CREATING A QUERY.................................................704 SORTING ON TRUCK UNIT NUMBER.................................704 SORTING ON TRUCK TYPE........................................704 SORTING ON DATE RANGE........................................705 SORTING ON TIME RANGE........................................705 PAYLOAD DETAIL SCREEN............................................706 CREATING REPORTS.................................................706 SUMMARY - ONE PAGE REPORT....................................707 DETAILED - MULTI PAGE REPORT.................................707 CREATING GRAPHS..................................................708 EXPORTING DATA...................................................708 CSV EXPORT...................................................708 COMPRESSED...................................................709 IMPORTING DATA...................................................710 DELETING HAUL CYCLE RECORDS......................................710 VIEWING ALARMS...................................................711 DELETING HAUL CYCLE RECORDS......................................711 VIEWING ALARMS...................................................711 DELETING ALARM RECORDS...........................................711 TROUBLESHOOTING SECTION..............................................712 TROUBLESHOOTING..................................................712 VIEWING ACTIVE ALARMS............................................712 REAL-TIME DATA DISPLAY...........................................712 TESTING THE PAYLOAD LIGHTS.......................................712 CREATING LOG FILES OF INPUTS.....................................713 DAILY INSPECTIONS................................................713 PERIODIC MAINTENANCE.............................................713 ABNORMAL DISPLAYS AT POWER-UP....................................714 NO PAYLOAD DISPLAY WHEN KEYSWITCH IS TURNED ON...................715 NO DISPLAY ON SPEEDOMETER........................................716 NO DISPLAY ON OPERATOR DISPLAY...................................716 NO COMMUNICATIONS WITH PC........................................717 LOAD LIGHTS DON'T LIGHT DURING LOADING...........................718 LOAD LIGHTS REMAIN ON............................................719 LOAD LIGHTS REMAIN ON DURING DUMPING.............................719 DISPLAY DOESN'T CLEAR WHEN THE LOAD IS DUMPED...................719 CALIBRATION PROBLEMS.............................................720 ALARM 1 - LEFT FRONT PRESSURE HIGH...............................721 ALARM 2 - LEFT FRONT PRESSURE LOW................................721 TROUBLESHOOT WIRING TO LEFT FRONT SUSPENSION.....................721 ALARM 3 - RIGHT FRONT PRESSURE HIGH..............................722 ALARM 4 - RIGHT FRONT PRESSURE LOW...............................722 TROUBLESHOOT WIRING TO RIGHT FRONT SUSPENSION....................722 ALARM 5 - LEFT REAR PRESSURE HIGH................................723 ALARM 6 - LEFT REAR PRESSURE LOW.................................723 TROUBLESHOOT WIRING TO LEFT REAR SUSPENSION......................723 ALARM 7 - RIGHT REAR PRESSURE HIGH...............................724 ALARM 8 - RIGHT REAR PRESSURE LOW................................724 TROUBLESHOOT WIRING TO RIGHT REAR SUSPENSION.....................724 ALARM 9 - INCLINOMETER HIGH......................................725 ALARM 10 - INCLINOMETER LOW......................................725 TROUBLESHOOTING INCLINOMETER WIRING..............................725 ALARM 13 - BODY UP INPUT FAILURE.................................726 ALARM 15 - MEMORY WRITE FAILURE..................................727 ALARM 16 - MEMORY READ FAILURE...................................727 ALARM 24 - SYSTEM KEY-ON STATUS..................................727 OPERATOR SWITCH DOESN'T WORK.....................................728 ALARM 26 - USER SWITCH FAULT - SELECT............................728 ALARM 27 - USER SWITCH FAULT - SET...............................728 CONNECTOR MAP....................................................729 CONNECTORS.......................................................730 CHECKOUT PROCEDURE SECTION...........................................732 PLM III CHECKOUT PROCEDURE.......................................732 GENERAL DESCRIPTION..........................................732 TOOLS REQUIRED...............................................732 CHECKOUT PROCEDURE...........................................732 PLM III CHECKOUT PROCEDURE CONFIRMATION..........................736 1.1 FLASHBURN PROGRAMMING - GENERAL INSTRUCTIONS.............736 CONFIRMATION CHECKLIST.......................................738 COMPONENTS AND SCHEMATICS SECTION....................................739 PAYLOAD METER III COMPONENTS.....................................739 PRESSURE SENSOR..............................................739 CONTROLLER...................................................739 SPEEDOMETER..................................................739 N. OPERATOR'S CAB............................................................740 TRUCK CAB................................................................742 DESCRIPTION..........................................................742 REMOVAL..........................................................743 INSTALLATION.....................................................744 CAB DOOR.............................................................745 REMOVAL..........................................................745 INSTALLATION.....................................................745 DOOR ADJUSTMENT..................................................745 DOOR GLASS REPLACEMENT...........................................748 DOOR HANDLE OR LATCH REPLACEMENT.................................752 DOOR AND DOOR HINGE SEAL REPLACEMENT.............................753 GLASS REPLACEMENT....................................................754 ADHESIVE BONDED WINDOWS..........................................754 WINDSHIELD AND REAR GLASS REPLACEMENT............................754 CAB COMPONENTS...........................................................758 WINDSHIELD WIPER.....................................................758 WINDSHIELD WASHER....................................................760 OPERATOR COMFORT.........................................................762 OPERATOR SEAT........................................................762 ADJUSTMENT.......................................................762 REMOVAL..........................................................762 INSTALLATION.....................................................762 HEATER / AIR CONDITIONER.................................................763 OPERATION............................................................763 HEATER COMPONENTS........................................................764 CIRCUIT BREAKERS.....................................................764 HEATER CONTROL COMPONENTS............................................764 HEATER CORE..........................................................765 FAN MOTOR AND SPEED CONTROL..........................................765 ACTUATORS............................................................765 FILTER...............................................................765 OPERATOR CONTROLS........................................................768 STEERING COLUMN......................................................770 REMOVAL..........................................................770 INSTALLATION.....................................................770 PEDAL CONTROLS.......................................................771 THROTTLE PEDAL...................................................771 SERVICE BRAKE PEDAL..............................................771 DUAL FUNCTION / SINGLE BRAKE PEDAL...............................771 DYNAMIC RETARDING PEDAL..........................................771 CONSOLE CONTROLS.........................................................773 INSTRUMENT PANEL.........................................................777 INDICATOR LIGHTS.........................................................783 CENTRY FUEL SYSTEM.......................................................789 DIAGNOSTICS.......................................................... 0 DETERMINING FAULT CODES.............................................. 0 P. LUBRICATION AND SERVICE...................................................792 LUBRICATION AND SERVICE..................................................794 SERVICE CAPACITIES...................................................794 HYDRAULIC TANK SERVICE...............................................794 HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS)........................ 0 COOLANT LEVEL CHECK..................................................795 RADIATOR FILLING PROCEDURE...........................................795 COOLING SYSTEM RECOMMENDATIONS.......................................795 LUBRICATION CHART....................................................796 10 HOURS.........................................................797 50 HOURS.........................................................799 100 HOURS........................................................799 250 HOURS........................................................800 500 HOURS........................................................802 1000 HOURS.......................................................803 5000 HOURS.......................................................803 LINCOLN AUTOMATIC LUBRICATION SYSTEM.....................................804 GENERAL DESCRIPTION..................................................804 SYSTEM COMPONENTS....................................................806 SYSTEM OPERATION.....................................................807 GENERAL INSTRUCTIONS.................................................810 SYSTEM PRIMING...................................................810 LUBRICANT PUMP...................................................810 FILTER AND RESERVOIR.............................................811 INJECTORS........................................................812 SYSTEM CHECK-OUT.....................................................813 24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT....................813 PUMP REBUILD.........................................................814 DISASSEMBLY......................................................814 CLEANING AND INSPECTION..........................................814 ASSEMBLY.........................................................816 PREVENTATIVE MAINTENANCE PROCEDURE................................... 0 MOTORIZED WHEEL MAINTENANCE SCHEDULE.....................................820 Q. ALPHABETICAL INDEX........................................................824 R. SYSTEM SCHEMATICS.........................................................828 HYDRAULIC BRAKE SYSTEM SCHEMATIC.........................................830 HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE).................................831 ELECTRICAL SCHEMATIC.....................................................832
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