Komatsu 730E DUMP TRUCK Shop Manual CEBM014700 PDF

Description

Komatsu 730E DUMP TRUCK Shop Manual CEBM014700 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E DUMP TRUCK Shop Manual CEBM014700 – PDF DOWNLOAD 

Language : English
Pages : 862
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 730E DUMP TRUCK Shop Manual CEBM014700 – PDF DOWNLOAD 

SERIAL NUMBERS A30299 – A30309 & A30311

FOREWORD:

• This Shop Manual is written for use by the service technician and is designed to help the technician become fullyknowledgeable 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.

TABLE OF CONTENTS:

Komatsu 730E DUMP TRUCK Shop Manual CEBM014700 – PDF DOWNLOAD 

SERIAL NUMBERS A30299 – A30309 & A30311

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

S.V 14/12/24