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Komatsu 730E Dump Truck Shop Manual CEBM011500 – PDF DOWNLOAD
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Komatsu 730E Dump Truck with TROLLEY ASSIST Shop Manual CEBM011500 – PDF DOWNLOAD
SERIAL NUMBERS
A30225 and A30226
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Description
Komatsu 730E Dump Truck with TROLLEY ASSIST Shop Manual CEBM011500 – PDF DOWNLOAD
FILE DETAILS:
Komatsu 730E Dump Truck with TROLLEY ASSIST Shop Manual CEBM011500 – PDF DOWNLOAD
Language : English
Pages :903
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu 730E Dump Truck with TROLLEY ASSIST Shop Manual CEBM011500 – PDF DOWNLOAD
SERIAL NUMBERS
A30225 and A30226
FOREWORD
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.
- For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% 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.
TABLE OF CONTENTS:
Komatsu 730E Dump Truck with TROLLEY ASSIST Shop Manual CEBM011500 – PDF DOWNLOAD
SERIAL NUMBERS
A30225 and A30226
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 44
CHARTS AND TABLES 52
STORAGE PROCEDURES 58
B STRUCTURES 78
STRUCTURAL COMPONENTS 80
GRILLE AND HOOD 80
LADDERS 81
DECKS 81
RIGHT DECK AND COMPONENTS 81
LEFT DECK 81
DUMP BODY 84
INSTALLATION 84
REMOVAL 84
BODY PADS 85
BODY GUIDE 86
BODY SLING 86
BODY POSITION INDICATOR 86
ROCK EJECTORS 87
HOIST LIMIT SWITCHES 87
FUEL TANK 88
REMOVAL 88
INSTALLATION 89
CLEANING 89
VENT 89
FUEL GAUGE SENDER 89
C ENGINE, FUEL, COOLING, AND AIR CLEANER 90
POWER MODULE 92
REMOVAL 92
INSTALLATION 96
COOLING SYSTEM 98
RADIATOR 98
REMOVAL 98
SERVICE 99
INSTALLATION 99
RADIATOR FILL PROCEDURE100
COOLING SYSTEM TROUBLESHOOTING101
POWER TRAIN102
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE102
REMOVAL102
ENGINE / ALTERNATOR MATING104
ALTERNATOR MEASUREMENT104
ENGINE END PLAY MEASUREMENT105
DETERMINING SHIM REQUIREMENTS105
INSTALLATION106
ENGINE108
REMOVAL108
INSTALLATION108
AIR CLEANERS110
FILTER ELEMENT REPLACEMENT110
MAIN FILTER ELEMENT CLEANING112
PRECLEANER SECTION113
D ELECTRIC SYSTEM (24 VDC, NON-PROPULSION)116
24 VDC ELECTRIC SUPPLY SYSTEM118
ELECTRICAL SYSTEM DESCRIPTION118
BATTERY – MAINTENANCE AND SERVICE118
ELECTRIC START SYSTEM120
OPERATION120
REMOVAL120
INSTALLATION120
CRANKING MOTOR TROUBLESHOOTING121
DISASSEMBLY122
SOLENOID CHECKS125
ASSEMBLY126
ENGINE PRELUB STARTER SYSTEM129
OPERATION129
TROUBLESHOOTING131
24 VDC ELECTRICAL SYSTEM COMPONENTS134
PASSENGER SEAT BASE COMPARTMENT134
TAIL LIGHT RESISTOR DIODE ASSEMBLIES134
5 MINUTE IDLE TIMER COMPONENTS134
ALARM INDICATING DEVICE (AID SYSTEM137
BODY UP SWITCH140
HOIST LIMIT SWITCH140
24 VDC RELAY AND DIODE BOARDS141
DESCRIPTION141
RELAY BOARD 1 (TURN SIGNAL)143
RELAY BOARD 2 (PAYLOAD METER)143
RELAY BOARD 3 (STOP LIGHTS)144
RELAY BOARD 4 (PARKING BRAKE)144
RELAY BOARD 5 (HEADLIGHTS)144
RELAY BOARD 6 (AUXILIARY PANEL)145
DIODE BOARD 1146
CIRCUIT BREAKER CHART147
E ELECTRIC PROPULSION AND CONTROL148
ELECTRICAL PROPULSION COMPONENTS150
GENERAL SYSTEM DESCRIPTION150
CONTROL SYSTEM150
FL275 PANEL152
COMPUTER DESCRIPTION154
SOFTWARE154
2-DIGIT DISPLAY PANEL157
EVENTS157
FRAMES158
WINDOWS158
EVENT CODE DESCRIPTIONS (TABLE I)166
SUBCODE DESCRIPTIONS (TABLE II)167
PORTABLE TEST UNIT (PTU)170
DESCRIPTION170
SOFTWARE INSTALLATION PREPARATION171
THE MAIN MENU173
PTU SOFTWARE MENU TREE174
CONFIGURATION (CFG) FILE CONVERSION175
STATEX CONFIGURATION FILES179
PROGRAMMING THE TRUCK190
PTU HOOKUP190
DOWNLOAD CONFIGURATION FILES192
EVENT DATA194
STATISTICAL DATA196
STATISTICAL DATA CODES – COUNTERS (TABLE III)198
STATISTICAL DATA CODES – PROFILES (TABLE IV)203
TRUCK SPECIFIC INFORMATION207
TEMPORARY TRUCK SETTINGS208
MISCELLANEOUS SOFTWARE FEATURES209
SAVING DATA209
PTU ABBREVIATIONS210
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS211
ALTERNATOR211
ELECTRIC WHEEL MOTORS211
RETARDING GRIDS211
ELECTRONIC ACCELERATOR AND RETARD CONTROL211
COOLING BLOWER WARNING SYSTEM213
ELECTRICAL CONTROL CABINET214
STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS219
ELECTRICAL CHECKOUT PROCEDURE222
G DRIVE AXLE, SPINDLES AND WHEELS274
TIRES AND RIMS (G02004)276
FRONT TIRES AND RIMS276
REMOVAL276
INSTALLATION277
REAR TIRES AND RIMS278
REMOVAL278
INSTALLATION279
RIM280
TIRE REMOVAL280
TIRE INSTALLATION281
FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)284
WHEEL HUB AND SPINDLE ASSEMBLY284
REMOVAL284
INSTALLATION286
DISASSEMBLY286
CLEANING AND INSPECTION287
ASSEMBLY287
WHEEL BEARING ADJUSTMENT (TIRE REMOVED)290
WHEEL BEARING ADJUSTMENT (TIRE MOUNTED)290
STEERING CYLINDERS AND TIE ROD292
REMOVAL293
INSTALLATION294
BEARING REPLACEMENT294
TOE-IN ADJUSTMENT295
REAR AXLE HOUSING ATTACHMENT (G04010)296
PIVOT PIN296
REMOVAL296
INSTALLATION296
DISASSEMBLY297
ASSEMBLY297
ANTI-SWAY BAR299
REMOVAL299
INSTALLATION299
DISASSEMBLY299
CLEANING AND INSPECTION299
ASSEMBLY299
REAR AXLE HOUSING (G05004)300
REAR AXLE HOUSING300
REMOVAL300
INSTALLATION300
WHEEL MOTOR300
REMOVAL300
CLEANING AND INSPECTION301
INSTALLATION301
H HYDRAIR II SUSPENSIONS302
FRONT SUSPENSION304
REMOVAL304
INSTALLATION305
DISASSEMBLY308
ASSEMBLY (BEARING RETAINER ONLY)310
ASSEMBLY (COMPLETE)310
SUSPENSION PRESSURE TEST311
REAR SUSPENSION312
REMOVAL313
INSTALLATION315
DISASSEMBLY315
ASSEMBLY316
SUSPENSION PRESSURE TEST318
OILING AND CHARGING PROCEDURES320
GENERAL320
EQUIPMENT LIST320
FRONT SUSPENSION322
FRONT SUSPENSION OILING322
FRONT SUSPENSION NITROGEN CHARGING323
REAR SUSPENSION324
REAR SUSPENSION OILING324
REAR SUSPENSION NITROGEN CHARGING326
OIL AND NITROGEN SPECIFICATIONS327
J BRAKE CIRCUIT328
BRAKE CIRCUIT330
SERVICE BRAKE CIRCUIT OPERATION330
SECONDARY BRAKING AND AUTOMATIC APPLY332
PARKING BRAKE CIRCUIT332
BRAKE LOCK CIRCUIT333
WARNING CIRCUIT333
BRAKE VALVE CUT-AWAY334
BRAKE CIRCUIT COMPONENT SERVICE336
BRAKE VALVE336
REMOVAL336
INSTALLATION338
DISASSEMBLY340
CLEANING AND INSPECTION342
ASSEMBLY342
BENCH TEST AND ADJUSTMENT346
INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE350
INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE352
HYDRAULIC BRAKE ACCUMULATORS353
REMOVAL353
INSTALLATION353
DISASSEMBLY353
CLEANING AND INSPECTION355
ASSEMBLY355
CHARGING PROCEDURE356
BRAKE CIRCUIT CHECKOUT PROCEDURE358
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING364
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET368
FRONT BRAKES (ROCKWELL)370
BRAKE CALIPER370
BRAKE LINING374
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE375
BRAKE BLEEDING PROCEDURE376
REAR BRAKES (ROCKWELL)378
BRAKE CALIPER, DISC AND PARKING BRAKE378
CALIPER PISTON ASSEMBLY383
BENCH TEST389
BRAKE LINING390
BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE394
BRAKE BLEEDING PROCEDURE395
PARKING BRAKE (ROCKWELL)396
PARK BRAKE CALIPER396
REMOVAL396
INSTALLATION397
PARKING BRAKE ADJUSTMENT 397
PARKING BRAKE ADJUSTMENT397
PARK BRAKE CALIPER DISASSEMBLY399
CLEANING AN INSPECTION399
PARK BRAKE CALIPER ASSEMBLY400
PARK BRAKE LINING401
REPLACEMENT 0
CONDITIONING (BURNISHING PROCEDURE) 0
BRAKE BLEEDING PROCEDURE401
L HYDRAULIC SYSTEM402
HYDRAULIC SYSTEM406
HOIST CIRCUIT OPERATION406
STEERING CIRCUIT OPERATION407
AXLE BLOWER OPERATION409
HYDRAULIC COMPONENT REPAIR412
HOIST PUMP412
REMOVAL412
INSTALLATION413
DISASSEMBLY414
INSPECTION416
ASSEMBLY417
TROUBLESHOOTING GUIDE421
PISTON PUMP422
REMOVAL422
INSTALLATION422
DISASSEMBLY424
INSPECTION430
ASSEMBLY432
AXLE BLOWER HYDRAULIC MOTOR436
REMOVAL436
INSTALLATION436
REAR AXLE BLOWER HOUSING436
DISASSEMBLY436
ASSEMBLY436
DISASSEMBLY438
INSPECTION440
ASSEMBLY441
TROUBLESHOOTING442
HAND WHEEL CONTROL443
DISASSEMBLY443
ASSEMBLY443
HYDRAULIC TANK445
FILLING INSTRUCTIONS445
REMOVAL446
INSTALLATION446
STRAINER AND DIFFUSER446
STEERING CIRCUIT448
STEERING CIRCUIT OPERATION448
COMPONENT DESCRIPTION449
STEERING CONTROL VALVE449
UNLOADER VALVE449
BLEED DOWN MANIFOLD VALVE450
FLOW AMPLIFIER454
STEERING PUMP463
ACCUMULATORS463
STEERING CONTROL VALVE464
REMOVAL464
INSTALLATION464
REBUILD PROCEDURE465
DISASSEMBLY465
CLEANING AND INSPECTION466
ASSEMBLY468
STEERING PUMP471
REMOVAL471
INSTALLATION471
DISASSEMBLY473
INSPECTION473
ASSEMBLY473
STEERING CIRCUIT COMPONENT REPAIR 0
BLEEDDOWN MANIFOLD VALVE 0
STEERING ACCUMULATORS 0
STEERING ACCUMULATORS CHARGING PROCEDURE 0
FLOW AMPLIFIER 0
STEERING CYLINDERS 0
HOIST CIRCUIT490
HOIST CIRCUIT OPERATION490
COMPONENT DESCRIPTION491
HOIST CIRCUIT COMPONENT REPAIR504
HOIST VALVE504
HOIST PILOT VALVE512
HOIST-UP LIMIT SOLENOID VALVE515
HOIST CYLINDERS515
HYDRAULIC SYSTEM FILTERS524
HOIST CIRCUIT FILTER524
STEERING CIRCUIT FILTER526
HYDRAULIC CHECKOUT PROCEDURES530
STEERING CIRCUIT TEST PROCEDURE530
COMPONENT LEAKAGE TEST532
TROUBLESHOOTING CHART534
CHECKING HOIST SYSTEM RELIEF VALVE PRESSURES537
POWER UP RELIEF PRESSURE TEST537
POWER DOWN RELIEF PRESSURE TEST538
HOIST COUNTERBALANCE VALVE ADJUSTMENT539
DISABLED TRUCK DUMPING PROCEDURE541
HYDRAULIC SYSTEM FLUSHING PROCEDURE542
HYDRAULIC SYSTEM TEST PROCEDURE545
M OPTIONS AND SPECIAL TOOLS548
FIRE CONTROL SYSTEMS550
ANSUL FIRE CONTROL PNEUMATIC SYSTEM550
ANSUL FIRE CONTROL ELECTRIC SYSTEM561
ANSUL FIRE CONTROL SYSTEM MANUAL566
OPERATION566
INSPECTION AND MAINTENANCE566
RECHARGING PROCEDURES567
ALTERNATOR AND WHEEL MOTOR COOLING AIR FILTER SYSTEM568
SYSTEM ADJUSTMENT568
PUMP568
BLOWER DRIVE MOTOR571
BLOWER BEARING REPAIR574
AIR CLEANER575
WIGGINS QUICK FILL FUEL SYSTEM576
TANK BREATHER VALVE577
FUEL RECEIVER578
FAN DRIVE CLUTCH – HYDRAULIC ACTUATED580
GENERAL DESCRIPTION580
MAINTENANCE583
TROUBLESHOOTING585
FIELD CHECK DIAGNOSIS586
THERMAL SENSOR AND SOLENOID VALVE587
TROUBLESHOOTING CHART590
DISASSEMBLY594
REASSEMBLY601
INSPECTION OF PARTS612
REBUILD TOOLS617
ENGINE COOLANT HEATER SYSTEM – HOT START – 220 VOLT618
HEATING ELEMENT618
THERMOSTAT619
ENGINE OIL HEATERS – HOT START – 220 VOLT620
TROUBLESHOOTING620
HEATING ELEMENT620
ENGINE AND COOLANT HEATERS – 440 VOLT622
TROUBLESHOOTING623
COOLANT HEATING ELEMENT624
OIL HEATING ELEMENT625
SPECIAL TOOL GROUP628
HEATER / AIR CONDITIONING SYSTEM636
ENVIRONMENTAL IMPACT636
OPERATOR CAB CONDITIONING637
PRINCIPLES OF REFRIGERATION637
MAJOR SYSTEM COMPONENTS639
SYSTEM SERVICING643
EVACUATING THE SYSTEM660
SYSTEM TROUBLESHOOTING662
24 VDC ELECTRIC SUPPLY SYSTEM672
ELECTRICAL SYSTEM DESCRIPTION672
BATTERY – MAINTENANCE AND SERVICE672
BATTERY CHARGING SYSTEM674
GENERAL DESCRIPTION674
TROUBLESHOOTING PROCEDURES674
NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL682
DIMENSIONS683
SPECIFICATIONS684
SERVICE PARTS LIST685
EXPLODED VIEW686
ON VEHICLE TEST688
BENCH TEST689
STATIC TESTS690
ALTERNATOR DISASSEMBLY693
ALTERNATOR ASSEMBLY698
SERVICE TOOL INSTRUCTIONS707
FUEL – WATER SEPARATOR710
INSTALLATION710
OPERATION710
FILTER SERVICE711
PAYLOAD METER III712
OPERATION SECTION715
INTRODUCTION715
DATA SUMMARY715
DATA GATHERING715
COMPONENT DESCRIPTION716
SYSTEM DIAGRAM716
SUSPENSION PRESSURE SENSORS716
INCLINOMETER716
OPERATOR DISPLAY716
OPERATOR SWITCH717
SPEED INPUT717
BODY – UP SWITCH717
BRAKE LOCK SWITCH717
PAYLOAD METER717
COMMUNICATIONS PORT717
KEYSWITCH INPUT718
PAYLOAD METER POWER718
LOAD LIGHTS718
WIRING AND TERMINATION719
TCI OUTPUTS719
OPERATOR’S DISPLAY AND SWITCH720
READING THE SPEEDOMETER720
READING THE LOAD DISPLAY720
USING THE OPERATOR ID720
USING THE LOAD AND TON COUNTER720
TOTAL TON COUNTER720
TOTAL LOAD COUNTER721
CLEARING THE COUNTERS721
VIEWING LIVE SENSOR DATA721
OTHER DISPLAY MESSAGES721
PAYLOAD OPERATION AND CALCULATION722
DESCRIPTION OF HAUL CYCLE STATES722
STATES OF HAUL CYLCLE722
HAUL CYCLE DESCRIPTION722
LOAD CALCULATION723
CARRY BACK723
MEASUREMENT ACCURACY723
SOURCES FOR PAYLOAD ERROR723
PAYLOAD ERROR717
LOADING CONDITIONS724
PRESSURE SENSORS724
SWINGLOADS724
SPEED AND DISTANCE724
HAUL CYCLE DATA725
HAUL CYCLE DATA725
HAUL CYCLE WARNING FLAGS726
ALARM RECORDS727
FRAME TORQUE DATA727
SPRUNG WEIGHT DATA728
MAXIMUM SPEED DATA728
PC SOFTWARE OVERVIEW728
PC OVERVIEW728
SYSTEM CONFIGURATION728
INSTALLING THE PAYLOAD METER III SOFTWARE728
DOWNLOADING DATA729
PLM III SYSTEM CONFIGURATION730
STARTING COMMUNICATIONS730
DISPLAYED PAYLOAD UNITS730
TIME UNITS730
CONNECTION MENU730
CONNECTING TO THE PAYLOAD METER731
CONFIGURE THE PAYLOAD METER731
SETTING THE DATE AND TIME731
SETTING THE TRUCK TYPE732
SETTING THE GAUGE DISPLAY UNITS732
SETTING THE FRAME SERIAL NUMBER732
SETTING THE TRUCK NUMBER732
SETTING THE KMS DISTRIBUTOR732
SETTING THE KMS CUSTOMER732
CLEAN TRUCK TARE733
INCLINOMETER CALIBRATION733
DATA ANALYSIS734
CREATING A QUERY734
SORTING ON TRUCK UNIT NUMBER734
SORTING ON TRUCK TYPE728
SORTING ON DATE RANGE735
SORTING ON TIME RANGE735
PAYLOAD DETAIL SCREEN736
CREATING REPORTS736
SUMMARY – ONE PAGE REPORT737
DETAILED – MULTI-PAGE REPORT737
CREATING GRAPHS738
EXPORTING DATA738
CSV EXPORT738
COMPRESSED739
IMPORTING DATA740
DELETING HAUL CYCLE RECORDS740
VIEWING ALARMS741
DELETING ALARM RECORDS741
TROUBLESHOOTING SECTION742
TROUBLESHOOTING742
VIEWING ACTIVE ALARMS742
REAL-TIME DATA DISPLAY742
TESTING THE PAYLOAD LIGHTS742
CREATING LOG FILES OF INPUTS743
DAILY INSPECTIONS743
PERIODIC MAINTENANCE743
ABNORMAL DISPLAYS AT POWER UP744
NO PAYLOAD DISPLAY WHEN KEYSWITCH IS ON745
NO DISPLAY ON SPEEDOMETER746
NO DISPLAY ON OPERATOR DISPLAY746
NO COMMUNICATIONS WITH PC747
LOAD LIGHTS DON’T LIGHT DURING LOADING748
LOAD LIGHTS REMAIN ON749
LOAD LIGHTS REMAIN ON DURING DUMPING749
DISPLAY DOESN’T CLEAR WHEN THE LOAD IS DUMPED749
CALIBRATION PROBLEMS750
ALARM 1 – LEFT FRONT PRESSURE HIGH751
ALARM 2- LEFT FRONT PRESSURE LOW751
TROUBLESHOOT WIRING TO LEFT FRONT SUSPENSION751
ALARM 3 – RIGHT FRONT PRESSURE HIGH752
ALARM 4 – RIGHT FRONT PRESSURE LOW752
TROUBLESHOOT WIRING TO RIGHT FRONT SUSPENSION752
ALARM 5 – LEFT REAR PRESSURE HIGH753
ALARM 6 – LEFT REAR PRESSURE LOW753
TROUBLESHOOT WIRING TO LEFT REAR SUSPENSION753
ALARM 7 – RIGHT REAR PRESSURE HIGH754
ALARM 8 – RIGHT REAR PRESSURE LOW754
TROUBLESHOOT WIRING TO RIGHT REAR SUSPENSION754
ALARM 9 – INCLINOMETER HIGH755
ALARM 10 – INCLINOMETER LOW755
TROUBLESHOOTING INCLINOMETER WIRING755
ALARM 13 – BODY UP INPUT FAILURE756
ALARM 15 – MEMORY WRITE FAILURE757
ALARM 16 – MEMORY READ FAILURE757
ALARM 24 – SYSTEM KEY-ON STATUS757
OPERATOR SWITCH DOESN’T WORK758
ALARM 26 – USER SWITCH FAULT – SELECT758
ALARM 27 – USER SWITCH FAULT – SET758
CONNECTOR MAP759
CONNECTORS760
CHECKOUT PROCEDURE SECTION762
PLM III CHECKOUT PROCEDURE762
GENERAL DESCRIPTION762
TOOLS REQUIRED762
CHECKOUT PROCEDURE762
PLM III CHECKOUT PROCEDURE CONFIRMATION766
11 FLASHBURN PROGRAMMING – GENERAL INSTRUCTIONS766
CONFIRMATION CHECKLIST768
COMPONENTS AND SCHEMATICS SECTION769
PAYLOAD METER III – COMPONENTS769
PRESSURE SENSOR769
CONTROLLER769
SPEEDOMETER769
N OPERATOR’S CAB770
TRUCK CAB772
DESCRIPTION772
REMOVAL773
INSTALLATION774
CAB DOOR775
REMOVAL775
INSTALLATION775
DOOR ADJUSTMENT775
DOOR GLASS REPLACEMENT778
DOOR HANDLE OR LATCH REPLACEMENT782
DOOR AND DOOR HINGE SEAL REPLACEMENT783
GLASS REPLACEMENT784
ADHESIVE BONDED WINDOWS784
WINDSHIELD AND REAR GLASS REPLACEMENT785
CAB COMPONENTS788
WINDSHIELD WIPER788
WINDSHIELD WASHER790
OPERATOR COMFORT792
OPERATOR SEAT792
ADJUSTMENT792
REMOVAL792
INSTALLATION792
HEATER / AIR CONDITIONER793
OPERATION793
HEATER COMPONENTS794
CIRCUIT BREAKERS794
HEATER CORE795
FAN MOTOR AND SPEED CONTROL795
ACTUATORS795
FILTER795
OPERATOR CONTROLS798
STEERING COLUMN799
REMOVAL799
INSTALLATION800
PEDAL CONTROLS801
THROTTLE PEDAL801
SERVICE BRAKE PEDAL801
DUAL FUNCTION / SINGLE BRAKE PEDAL801
DYNAMIC RETARDING PEDAL801
CONSOLE CONTROLS803
INSTRUMENT PANEL807
OVERHEAD CONTROLS, GAUGES813
INDICATOR LIGHTS814
CENTRY FUEL SYSTEM821
DETERMINING FAULT CODES821
P LUBRICATION AND SERVICE830
LUBRICATION AND SERVICE832
SERVICE CAPACITIES832
HYDRAULIC TANK SERVICE832
HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS)832
COOLANT LEVEL CHECK833
RADIATOR FILLING PROCEDURE833
COOLING SYSTEM RECOMMENDATIONS833
LUBRICATION CHART834
10 HOURS835
50 HOURS837
100 HOURS838
250 HOURS839
500 HOURS841
1000 HOURS842
5000 HOURS843
LINCOLN AUTOMATIC LUBRICATION SYSTEM844
GENERAL DESCRIPTION844
SYSTEM COMPONENTS846
SYSTEM OPERATION829
GENERAL INSTRUCTIONS850
SYSTEM PRIMING850
LUBRICANT PUMP850
FILTER AND RESERVOIR851
INJECTORS852
SYSTEM CHECK-OUT853
24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT853
PUMP REBUILD854
DISASSEMBLY854
CLEANING AND INSPECTION854
ASSEMBLY856
PREVENTATIVE MAINTENANCE PROCEDURE860
MOTORIZED WHEEL MAINTENANCE SCHEDULE862
Q ALPHABETICAL INDEX866
R SYSTEM SCHEMATICS870
HYDRAULIC BRAKE SYSTEM SCHEMATIC872
HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE)873
ELECTRICAL SCHEMATIC874
PAYLOAD METER III ELECTRICAL SCHEMATIC902
COVER 1
FOREWARD 4
CONTENTS 6
A GENERAL INFORMATION 8
TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS 10
GENERAL SAFETY AND TRUCK OPERATION 14
WARNINGS AND CAUTIONS 44
CHARTS AND TABLES 52
STORAGE PROCEDURES 58
B STRUCTURES 78
STRUCTURAL COMPONENTS 80
GRILLE AND HOOD 80
LADDERS 81
DECKS 81
RIGHT DECK AND COMPONENTS 81
LEFT DECK 81
DUMP BODY 84
INSTALLATION 84
REMOVAL 84
BODY PADS 85
BODY GUIDE 86
BODY SLING 86
BODY POSITION INDICATOR 86
ROCK EJECTORS 87
HOIST LIMIT SWITCHES 87
FUEL TANK 88
REMOVAL 88
INSTALLATION 89
CLEANING 89
VENT 89
FUEL GAUGE SENDER 89
C ENGINE, FUEL, COOLING, AND AIR CLEANER 90
POWER MODULE 92
REMOVAL 92
INSTALLATION 96
COOLING SYSTEM 98
RADIATOR 98
REMOVAL 98
SERVICE 99
INSTALLATION 99
RADIATOR FILL PROCEDURE100
COOLING SYSTEM TROUBLESHOOTING101
POWER TRAIN102
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE102
REMOVAL102
ENGINE / ALTERNATOR MATING104
ALTERNATOR MEASUREMENT104
ENGINE END PLAY MEASUREMENT105
DETERMINING SHIM REQUIREMENTS105
INSTALLATION106
ENGINE108
REMOVAL108
INSTALLATION108
AIR CLEANERS110
FILTER ELEMENT REPLACEMENT110
MAIN FILTER ELEMENT CLEANING112
PRECLEANER SECTION113
D ELECTRIC SYSTEM (24 VDC, NON-PROPULSION)116
24 VDC ELECTRIC SUPPLY SYSTEM118
ELECTRICAL SYSTEM DESCRIPTION118
BATTERY – MAINTENANCE AND SERVICE118
ELECTRIC START SYSTEM120
OPERATION120
REMOVAL120
INSTALLATION120
CRANKING MOTOR TROUBLESHOOTING121
DISASSEMBLY122
SOLENOID CHECKS125
ASSEMBLY126
ENGINE PRELUB STARTER SYSTEM129
OPERATION129
TROUBLESHOOTING131
24 VDC ELECTRICAL SYSTEM COMPONENTS134
PASSENGER SEAT BASE COMPARTMENT134
TAIL LIGHT RESISTOR DIODE ASSEMBLIES134
5 MINUTE IDLE TIMER COMPONENTS134
ALARM INDICATING DEVICE (AID SYSTEM137
BODY UP SWITCH140
HOIST LIMIT SWITCH140
24 VDC RELAY AND DIODE BOARDS141
DESCRIPTION141
RELAY BOARD 1 (TURN SIGNAL)143
RELAY BOARD 2 (PAYLOAD METER)143
RELAY BOARD 3 (STOP LIGHTS)144
RELAY BOARD 4 (PARKING BRAKE)144
RELAY BOARD 5 (HEADLIGHTS)144
RELAY BOARD 6 (AUXILIARY PANEL)145
DIODE BOARD 1146
CIRCUIT BREAKER CHART147
E ELECTRIC PROPULSION AND CONTROL148
ELECTRICAL PROPULSION COMPONENTS150
GENERAL SYSTEM DESCRIPTION150
CONTROL SYSTEM150
FL275 PANEL152
COMPUTER DESCRIPTION154
SOFTWARE154
2-DIGIT DISPLAY PANEL157
EVENTS157
FRAMES158
WINDOWS158
EVENT CODE DESCRIPTIONS (TABLE I)166
SUBCODE DESCRIPTIONS (TABLE II)167
PORTABLE TEST UNIT (PTU)170
DESCRIPTION170
SOFTWARE INSTALLATION PREPARATION171
THE MAIN MENU173
PTU SOFTWARE MENU TREE174
CONFIGURATION (CFG) FILE CONVERSION175
STATEX CONFIGURATION FILES179
PROGRAMMING THE TRUCK190
PTU HOOKUP190
DOWNLOAD CONFIGURATION FILES192
EVENT DATA194
STATISTICAL DATA196
STATISTICAL DATA CODES – COUNTERS (TABLE III)198
STATISTICAL DATA CODES – PROFILES (TABLE IV)203
TRUCK SPECIFIC INFORMATION207
TEMPORARY TRUCK SETTINGS208
MISCELLANEOUS SOFTWARE FEATURES209
SAVING DATA209
PTU ABBREVIATIONS210
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS211
ALTERNATOR211
ELECTRIC WHEEL MOTORS211
RETARDING GRIDS211
ELECTRONIC ACCELERATOR AND RETARD CONTROL211
COOLING BLOWER WARNING SYSTEM213
ELECTRICAL CONTROL CABINET214
STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS219
ELECTRICAL CHECKOUT PROCEDURE222
G DRIVE AXLE, SPINDLES AND WHEELS274
TIRES AND RIMS (G02004)276
FRONT TIRES AND RIMS276
REMOVAL276
INSTALLATION277
REAR TIRES AND RIMS278
REMOVAL278
INSTALLATION279
RIM280
TIRE REMOVAL280
TIRE INSTALLATION281
FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)284
WHEEL HUB AND SPINDLE ASSEMBLY284
REMOVAL284
INSTALLATION286
DISASSEMBLY286
CLEANING AND INSPECTION287
ASSEMBLY287
WHEEL BEARING ADJUSTMENT (TIRE REMOVED)290
WHEEL BEARING ADJUSTMENT (TIRE MOUNTED)290
STEERING CYLINDERS AND TIE ROD292
REMOVAL293
INSTALLATION294
BEARING REPLACEMENT294
TOE-IN ADJUSTMENT295
REAR AXLE HOUSING ATTACHMENT (G04010)296
PIVOT PIN296
REMOVAL296
INSTALLATION296
DISASSEMBLY297
ASSEMBLY297
ANTI-SWAY BAR299
REMOVAL299
INSTALLATION299
DISASSEMBLY299
CLEANING AND INSPECTION299
ASSEMBLY299
REAR AXLE HOUSING (G05004)300
REAR AXLE HOUSING300
REMOVAL300
INSTALLATION300
WHEEL MOTOR300
REMOVAL300
CLEANING AND INSPECTION301
INSTALLATION301
H HYDRAIR II SUSPENSIONS302
FRONT SUSPENSION304
REMOVAL304
INSTALLATION305
DISASSEMBLY308
ASSEMBLY (BEARING RETAINER ONLY)310
ASSEMBLY (COMPLETE)310
SUSPENSION PRESSURE TEST311
REAR SUSPENSION312
REMOVAL313
INSTALLATION315
DISASSEMBLY315
ASSEMBLY316
SUSPENSION PRESSURE TEST318
OILING AND CHARGING PROCEDURES320
GENERAL320
EQUIPMENT LIST320
FRONT SUSPENSION322
FRONT SUSPENSION OILING322
FRONT SUSPENSION NITROGEN CHARGING323
REAR SUSPENSION324
REAR SUSPENSION OILING324
REAR SUSPENSION NITROGEN CHARGING326
OIL AND NITROGEN SPECIFICATIONS327
J BRAKE CIRCUIT328
BRAKE CIRCUIT330
SERVICE BRAKE CIRCUIT OPERATION330
SECONDARY BRAKING AND AUTOMATIC APPLY332
PARKING BRAKE CIRCUIT332
BRAKE LOCK CIRCUIT333
WARNING CIRCUIT333
BRAKE VALVE CUT-AWAY334
BRAKE CIRCUIT COMPONENT SERVICE336
BRAKE VALVE336
REMOVAL336
INSTALLATION338
DISASSEMBLY340
CLEANING AND INSPECTION342
ASSEMBLY342
BENCH TEST AND ADJUSTMENT346
INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE350
INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE352
HYDRAULIC BRAKE ACCUMULATORS353
REMOVAL353
INSTALLATION353
DISASSEMBLY353
CLEANING AND INSPECTION355
ASSEMBLY355
CHARGING PROCEDURE356
BRAKE CIRCUIT CHECKOUT PROCEDURE358
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING364
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET368
FRONT BRAKES (ROCKWELL)370
BRAKE CALIPER370
BRAKE LINING374
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE375
BRAKE BLEEDING PROCEDURE376
REAR BRAKES (ROCKWELL)378
BRAKE CALIPER, DISC AND PARKING BRAKE378
CALIPER PISTON ASSEMBLY383
BENCH TEST389
BRAKE LINING390
BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE394
BRAKE BLEEDING PROCEDURE395
PARKING BRAKE (ROCKWELL)396
PARK BRAKE CALIPER396
REMOVAL396
INSTALLATION397
PARKING BRAKE ADJUSTMENT 397
PARKING BRAKE ADJUSTMENT397
PARK BRAKE CALIPER DISASSEMBLY399
CLEANING AN INSPECTION399
PARK BRAKE CALIPER ASSEMBLY400
PARK BRAKE LINING401
REPLACEMENT 0
CONDITIONING (BURNISHING PROCEDURE) 0
BRAKE BLEEDING PROCEDURE401
L HYDRAULIC SYSTEM402
HYDRAULIC SYSTEM406
HOIST CIRCUIT OPERATION406
STEERING CIRCUIT OPERATION407
AXLE BLOWER OPERATION409
HYDRAULIC COMPONENT REPAIR412
HOIST PUMP412
REMOVAL412
INSTALLATION413
DISASSEMBLY414
INSPECTION416
ASSEMBLY417
TROUBLESHOOTING GUIDE421
PISTON PUMP422
REMOVAL422
INSTALLATION422
DISASSEMBLY424
INSPECTION430
ASSEMBLY432
AXLE BLOWER HYDRAULIC MOTOR436
REMOVAL436
INSTALLATION436
REAR AXLE BLOWER HOUSING436
DISASSEMBLY436
ASSEMBLY436
DISASSEMBLY438
INSPECTION440
ASSEMBLY441
TROUBLESHOOTING442
HAND WHEEL CONTROL443
DISASSEMBLY443
ASSEMBLY443
HYDRAULIC TANK445
FILLING INSTRUCTIONS445
REMOVAL446
INSTALLATION446
STRAINER AND DIFFUSER446
STEERING CIRCUIT448
STEERING CIRCUIT OPERATION448
COMPONENT DESCRIPTION449
STEERING CONTROL VALVE449
UNLOADER VALVE449
BLEED DOWN MANIFOLD VALVE450
FLOW AMPLIFIER454
STEERING PUMP463
ACCUMULATORS463
STEERING CONTROL VALVE464
REMOVAL464
INSTALLATION464
REBUILD PROCEDURE465
DISASSEMBLY465
CLEANING AND INSPECTION466
ASSEMBLY468
STEERING PUMP471
REMOVAL471
INSTALLATION471
DISASSEMBLY473
INSPECTION473
ASSEMBLY473
STEERING CIRCUIT COMPONENT REPAIR 0
BLEEDDOWN MANIFOLD VALVE 0
STEERING ACCUMULATORS 0
STEERING ACCUMULATORS CHARGING PROCEDURE 0
FLOW AMPLIFIER 0
STEERING CYLINDERS 0
HOIST CIRCUIT490
HOIST CIRCUIT OPERATION490
COMPONENT DESCRIPTION491
HOIST CIRCUIT COMPONENT REPAIR504
HOIST VALVE504
HOIST PILOT VALVE512
HOIST-UP LIMIT SOLENOID VALVE515
HOIST CYLINDERS515
HYDRAULIC SYSTEM FILTERS524
HOIST CIRCUIT FILTER524
STEERING CIRCUIT FILTER526
HYDRAULIC CHECKOUT PROCEDURES530
STEERING CIRCUIT TEST PROCEDURE530
COMPONENT LEAKAGE TEST532
TROUBLESHOOTING CHART534
CHECKING HOIST SYSTEM RELIEF VALVE PRESSURES537
POWER UP RELIEF PRESSURE TEST537
POWER DOWN RELIEF PRESSURE TEST538
HOIST COUNTERBALANCE VALVE ADJUSTMENT539
DISABLED TRUCK DUMPING PROCEDURE541
HYDRAULIC SYSTEM FLUSHING PROCEDURE542
HYDRAULIC SYSTEM TEST PROCEDURE545
M OPTIONS AND SPECIAL TOOLS548
FIRE CONTROL SYSTEMS550
ANSUL FIRE CONTROL PNEUMATIC SYSTEM550
ANSUL FIRE CONTROL ELECTRIC SYSTEM561
ANSUL FIRE CONTROL SYSTEM MANUAL566
OPERATION566
INSPECTION AND MAINTENANCE566
RECHARGING PROCEDURES567
ALTERNATOR AND WHEEL MOTOR COOLING AIR FILTER SYSTEM568
SYSTEM ADJUSTMENT568
PUMP568
BLOWER DRIVE MOTOR571
BLOWER BEARING REPAIR574
AIR CLEANER575
WIGGINS QUICK FILL FUEL SYSTEM576
TANK BREATHER VALVE577
FUEL RECEIVER578
FAN DRIVE CLUTCH – HYDRAULIC ACTUATED580
GENERAL DESCRIPTION580
MAINTENANCE583
TROUBLESHOOTING585
FIELD CHECK DIAGNOSIS586
THERMAL SENSOR AND SOLENOID VALVE587
TROUBLESHOOTING CHART590
DISASSEMBLY594
REASSEMBLY601
INSPECTION OF PARTS612
REBUILD TOOLS617
ENGINE COOLANT HEATER SYSTEM – HOT START – 220 VOLT618
HEATING ELEMENT618
THERMOSTAT619
ENGINE OIL HEATERS – HOT START – 220 VOLT620
TROUBLESHOOTING620
HEATING ELEMENT620
ENGINE AND COOLANT HEATERS – 440 VOLT622
TROUBLESHOOTING623
COOLANT HEATING ELEMENT624
OIL HEATING ELEMENT625
SPECIAL TOOL GROUP628
HEATER / AIR CONDITIONING SYSTEM636
ENVIRONMENTAL IMPACT636
OPERATOR CAB CONDITIONING637
PRINCIPLES OF REFRIGERATION637
MAJOR SYSTEM COMPONENTS639
SYSTEM SERVICING643
EVACUATING THE SYSTEM660
SYSTEM TROUBLESHOOTING662
24 VDC ELECTRIC SUPPLY SYSTEM672
ELECTRICAL SYSTEM DESCRIPTION672
BATTERY – MAINTENANCE AND SERVICE672
BATTERY CHARGING SYSTEM674
GENERAL DESCRIPTION674
TROUBLESHOOTING PROCEDURES674
NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL682
DIMENSIONS683
SPECIFICATIONS684
SERVICE PARTS LIST685
EXPLODED VIEW686
ON VEHICLE TEST688
BENCH TEST689
STATIC TESTS690
ALTERNATOR DISASSEMBLY693
ALTERNATOR ASSEMBLY698
SERVICE TOOL INSTRUCTIONS707
FUEL – WATER SEPARATOR710
INSTALLATION710
OPERATION710
FILTER SERVICE711
PAYLOAD METER III712
OPERATION SECTION715
INTRODUCTION715
DATA SUMMARY715
DATA GATHERING715
COMPONENT DESCRIPTION716
SYSTEM DIAGRAM716
SUSPENSION PRESSURE SENSORS716
INCLINOMETER716
OPERATOR DISPLAY716
OPERATOR SWITCH717
SPEED INPUT717
BODY – UP SWITCH717
BRAKE LOCK SWITCH717
PAYLOAD METER717
COMMUNICATIONS PORT717
KEYSWITCH INPUT718
PAYLOAD METER POWER718
LOAD LIGHTS718
WIRING AND TERMINATION719
TCI OUTPUTS719
OPERATOR’S DISPLAY AND SWITCH720
READING THE SPEEDOMETER720
READING THE LOAD DISPLAY720
USING THE OPERATOR ID720
USING THE LOAD AND TON COUNTER720
TOTAL TON COUNTER720
TOTAL LOAD COUNTER721
CLEARING THE COUNTERS721
VIEWING LIVE SENSOR DATA721
OTHER DISPLAY MESSAGES721
PAYLOAD OPERATION AND CALCULATION722
DESCRIPTION OF HAUL CYCLE STATES722
STATES OF HAUL CYLCLE722
HAUL CYCLE DESCRIPTION722
LOAD CALCULATION723
CARRY BACK723
MEASUREMENT ACCURACY723
SOURCES FOR PAYLOAD ERROR723
PAYLOAD ERROR717
LOADING CONDITIONS724
PRESSURE SENSORS724
SWINGLOADS724
SPEED AND DISTANCE724
HAUL CYCLE DATA725
HAUL CYCLE DATA725
HAUL CYCLE WARNING FLAGS726
ALARM RECORDS727
FRAME TORQUE DATA727
SPRUNG WEIGHT DATA728
MAXIMUM SPEED DATA728
PC SOFTWARE OVERVIEW728
PC OVERVIEW728
SYSTEM CONFIGURATION728
INSTALLING THE PAYLOAD METER III SOFTWARE728
DOWNLOADING DATA729
PLM III SYSTEM CONFIGURATION730
STARTING COMMUNICATIONS730
DISPLAYED PAYLOAD UNITS730
TIME UNITS730
CONNECTION MENU730
CONNECTING TO THE PAYLOAD METER731
CONFIGURE THE PAYLOAD METER731
SETTING THE DATE AND TIME731
SETTING THE TRUCK TYPE732
SETTING THE GAUGE DISPLAY UNITS732
SETTING THE FRAME SERIAL NUMBER732
SETTING THE TRUCK NUMBER732
SETTING THE KMS DISTRIBUTOR732
SETTING THE KMS CUSTOMER732
CLEAN TRUCK TARE733
INCLINOMETER CALIBRATION733
DATA ANALYSIS734
CREATING A QUERY734
SORTING ON TRUCK UNIT NUMBER734
SORTING ON TRUCK TYPE728
SORTING ON DATE RANGE735
SORTING ON TIME RANGE735
PAYLOAD DETAIL SCREEN736
CREATING REPORTS736
SUMMARY – ONE PAGE REPORT737
DETAILED – MULTI-PAGE REPORT737
CREATING GRAPHS738
EXPORTING DATA738
CSV EXPORT738
COMPRESSED739
IMPORTING DATA740
DELETING HAUL CYCLE RECORDS740
VIEWING ALARMS741
DELETING ALARM RECORDS741
TROUBLESHOOTING SECTION742
TROUBLESHOOTING742
VIEWING ACTIVE ALARMS742
REAL-TIME DATA DISPLAY742
TESTING THE PAYLOAD LIGHTS742
CREATING LOG FILES OF INPUTS743
DAILY INSPECTIONS743
PERIODIC MAINTENANCE743
ABNORMAL DISPLAYS AT POWER UP744
NO PAYLOAD DISPLAY WHEN KEYSWITCH IS ON745
NO DISPLAY ON SPEEDOMETER746
NO DISPLAY ON OPERATOR DISPLAY746
NO COMMUNICATIONS WITH PC747
LOAD LIGHTS DON’T LIGHT DURING LOADING748
LOAD LIGHTS REMAIN ON749
LOAD LIGHTS REMAIN ON DURING DUMPING749
DISPLAY DOESN’T CLEAR WHEN THE LOAD IS DUMPED749
CALIBRATION PROBLEMS750
ALARM 1 – LEFT FRONT PRESSURE HIGH751
ALARM 2- LEFT FRONT PRESSURE LOW751
TROUBLESHOOT WIRING TO LEFT FRONT SUSPENSION751
ALARM 3 – RIGHT FRONT PRESSURE HIGH752
ALARM 4 – RIGHT FRONT PRESSURE LOW752
TROUBLESHOOT WIRING TO RIGHT FRONT SUSPENSION752
ALARM 5 – LEFT REAR PRESSURE HIGH753
ALARM 6 – LEFT REAR PRESSURE LOW753
TROUBLESHOOT WIRING TO LEFT REAR SUSPENSION753
ALARM 7 – RIGHT REAR PRESSURE HIGH754
ALARM 8 – RIGHT REAR PRESSURE LOW754
TROUBLESHOOT WIRING TO RIGHT REAR SUSPENSION754
ALARM 9 – INCLINOMETER HIGH755
ALARM 10 – INCLINOMETER LOW755
TROUBLESHOOTING INCLINOMETER WIRING755
ALARM 13 – BODY UP INPUT FAILURE756
ALARM 15 – MEMORY WRITE FAILURE757
ALARM 16 – MEMORY READ FAILURE757
ALARM 24 – SYSTEM KEY-ON STATUS757
OPERATOR SWITCH DOESN’T WORK758
ALARM 26 – USER SWITCH FAULT – SELECT758
ALARM 27 – USER SWITCH FAULT – SET758
CONNECTOR MAP759
CONNECTORS760
CHECKOUT PROCEDURE SECTION762
PLM III CHECKOUT PROCEDURE762
GENERAL DESCRIPTION762
TOOLS REQUIRED762
CHECKOUT PROCEDURE762
PLM III CHECKOUT PROCEDURE CONFIRMATION766
11 FLASHBURN PROGRAMMING – GENERAL INSTRUCTIONS766
CONFIRMATION CHECKLIST768
COMPONENTS AND SCHEMATICS SECTION769
PAYLOAD METER III – COMPONENTS769
PRESSURE SENSOR769
CONTROLLER769
SPEEDOMETER769
N OPERATOR’S CAB770
TRUCK CAB772
DESCRIPTION772
REMOVAL773
INSTALLATION774
CAB DOOR775
REMOVAL775
INSTALLATION775
DOOR ADJUSTMENT775
DOOR GLASS REPLACEMENT778
DOOR HANDLE OR LATCH REPLACEMENT782
DOOR AND DOOR HINGE SEAL REPLACEMENT783
GLASS REPLACEMENT784
ADHESIVE BONDED WINDOWS784
WINDSHIELD AND REAR GLASS REPLACEMENT785
CAB COMPONENTS788
WINDSHIELD WIPER788
WINDSHIELD WASHER790
OPERATOR COMFORT792
OPERATOR SEAT792
ADJUSTMENT792
REMOVAL792
INSTALLATION792
HEATER / AIR CONDITIONER793
OPERATION793
HEATER COMPONENTS794
CIRCUIT BREAKERS794
HEATER CORE795
FAN MOTOR AND SPEED CONTROL795
ACTUATORS795
FILTER795
OPERATOR CONTROLS798
STEERING COLUMN799
REMOVAL799
INSTALLATION800
PEDAL CONTROLS801
THROTTLE PEDAL801
SERVICE BRAKE PEDAL801
DUAL FUNCTION / SINGLE BRAKE PEDAL801
DYNAMIC RETARDING PEDAL801
CONSOLE CONTROLS803
INSTRUMENT PANEL807
OVERHEAD CONTROLS, GAUGES813
INDICATOR LIGHTS814
CENTRY FUEL SYSTEM821
DETERMINING FAULT CODES821
P LUBRICATION AND SERVICE830
LUBRICATION AND SERVICE832
SERVICE CAPACITIES832
HYDRAULIC TANK SERVICE832
HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS)832
COOLANT LEVEL CHECK833
RADIATOR FILLING PROCEDURE833
COOLING SYSTEM RECOMMENDATIONS833
LUBRICATION CHART834
10 HOURS835
50 HOURS837
100 HOURS838
250 HOURS839
500 HOURS841
1000 HOURS842
5000 HOURS843
LINCOLN AUTOMATIC LUBRICATION SYSTEM844
GENERAL DESCRIPTION844
SYSTEM COMPONENTS846
SYSTEM OPERATION829
GENERAL INSTRUCTIONS850
SYSTEM PRIMING850
LUBRICANT PUMP850
FILTER AND RESERVOIR851
INJECTORS852
SYSTEM CHECK-OUT853
24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT853
PUMP REBUILD854
DISASSEMBLY854
CLEANING AND INSPECTION854
ASSEMBLY856
PREVENTATIVE MAINTENANCE PROCEDURE860
MOTORIZED WHEEL MAINTENANCE SCHEDULE862
Q ALPHABETICAL INDEX866
R SYSTEM SCHEMATICS870
HYDRAULIC BRAKE SYSTEM SCHEMATIC872
HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE)873
ELECTRICAL SCHEMATIC874
PAYLOAD METER III ELECTRICAL SCHEMATIC902
IMAGES PREVIEW OF THE MANUAL:
S.M 14/12/24
