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Komatsu 730E Dump Truck Shop Manual SN A30219-A30259 – PDF DOWNLOAD
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Komatsu 730E Dump Truck Shop Manual
Book Code: CEBM011002
SERIAL NUMBERS A30219 – A30259
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Description
Komatsu 730E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 730E Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 730E
Serial Number: A30219-A30259
Book Code: CEBM011002
Language: English
Pages: 851
File Format: Portable Document Format (PDF)
KOMATSU 730E DUMP TRUCK SHOP MANUAL SN A30219-A30259 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 730E Dump Truck Shop Manual
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 Shop Manual
MAIN MENU................................................................... 0 COVER....................................................................... 1 FOREWORD.................................................................... 4 CONTENTS.................................................................... 6 A. GENERAL INFORMATION...................................................... 8 TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS............................ 10 GENERAL SAFETY AND TRUCK OPERATION...................................... 14 WARNINGS AND CAUTIONS................................................... 38 CHARTS AND TABLES....................................................... 46 STORAGE PROCEDURES...................................................... 52 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).................................110 24 VDC ELECTRIC SUPPLY SYSTEM...........................................112 ELECTRICAL SYSTEM DESCRIPTION.......................................112 BATTERY - MAINTENANCE AND SERVICE...................................112 ELECTRIC START SYSTEM...............................................114 OPERATION.......................................................114 REMOVAL.....................................................114 INSTALLATION................................................114 CRANKING MOTOR TROUBLESHOOTING..................................115 DISASSEMBLY.....................................................116 SOLENOID CHECKS.................................................119 ASSEMBLY........................................................120 ENGINE PRELUB STARTER SYSTEM........................................123 OPERATION.......................................................123 TROUBLESHOOTING.................................................125 24 VDC ELECTRICAL SYSTEM COMPONENTS.....................................128 PASSENGER SEAT BASE COMPARTMENT.....................................128 TAIL LIGHT RESISTOR DIODE ASSEMBLIES............................128 5 MINUTE IDLE TIMER COMPONENTS..................................130 ALARM INDICATING DEVICE (A.I.D. SYSTEM).........................131 BODY UP SWITCH......................................................134 HOIST LIMIT SWITCH..................................................134 24 VDC RELAY AND DIODE BOARDS.......................................135 DESCRIPTION.....................................................135 RELAY BOARD 1 (TURN SIGNAL).....................................137 RELAY BOARD 2 (PAYLOAD METER)...................................137 RELAY BOARD 3 (STOP LIGHTS).....................................138 RELAY BOARD 4 (PARKING BRAKE)...................................138 RELAY BOARD 5 (HEADLIGHTS)......................................138 RELAY BOARD 6 (AUXILIARY PANEL).................................139 DIODE BOARD 1...................................................140 CIRCUIT BREAKER CHART...........................................141 E. ELECTRIC PROPULSION AND CONTROL..........................................142 ELECTRICAL PROPULSION COMPONENTS........................................144 GENERAL SYSTEM DESCRIPTION..........................................144 CONTROL SYSTEM......................................................144 FL275 PANEL.........................................................146 COMPUTER DESCRIPTION............................................148 SOFTWARE........................................................148 2-DIGIT DISPLAY PANEL...............................................151 EVENTS..........................................................151 FRAMES..........................................................152 WINDOWS.........................................................152 EVENT CODE DESCRIPTIONS (TABLE I)...........................154 SUBCODE DESCRIPTIONS (TABLE II).............................161 PORTABLE TEST UNIT (PTU)............................................164 DESCRIPTION.....................................................164 SOFTWARE INSTALLATION PREPARATION...............................165 THE MAIN MENU...............................................167 PTU SOFTWARE MENU TREE......................................168 CONFIGURATION (CFG) FILE CONVERSION.........................169 STATEX CONFIGURATION FILES......................................173 PROGRAMMING THE TRUCK...........................................184 PTU HOOKUP..................................................184 DOWNLOAD CONFIGURATION FILES................................186 EVENT DATA......................................................188 STATISTICAL DATA................................................191 STATISTICAL DATA CODES - COUNTERS (TABLE III)...............192 STATISTICAL DATA CODES - PROFILES (TABLE IV)................197 TRUCK SPECIFIC INFORMATION......................................201 TEMPORARY TRUCK SETTINGS........................................202 MISCELLANEOUS SOFTWARE FEATURES.................................203 SAVING DATA.................................................203 PTU ABBREVIATIONS...........................................204 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..........................205 ALTERNATOR..........................................................205 ELECTRIC WHEEL MOTORS...............................................205 RETARDING GRIDS.....................................................205 ELECTRONIC ACCELERATOR AND RETARD CONTROL...........................205 COOLING BLOWER WARNING SYSTEM.......................................207 ELECTRICAL CONTROL CABINET..........................................208 STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS..................213 ELECTRICAL CHECKOUT PROCEDURE...........................................216 G. DRIVE AXLE, SPINDLES AND WHEELS..........................................268 TIRES AND RIMS (G02012).................................................270 FRONT TIRES AND RIMS................................................271 REMOVAL.........................................................271 INSTALLATION....................................................272 REAR TIRES AND RIMS.................................................272 REMOVAL.........................................................272 INSTALLATION....................................................273 RIM.................................................................274 TIRE REMOVAL....................................................274 TIRE INSTALLATION...............................................275 FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)...........................276 WHEEL HUB AND SPINDLE ASSEMBLY......................................276 REMOVAL......................................................... 0 INSTALLATION....................................................278 DISASSEMBLY.....................................................278 CLEANING AND INSPECTION.........................................279 ASSEMBLY........................................................279 WHEEL BEARING ADJUSTMENT (TIRE REMOVED).........................281 WHEEL BEARING ADJUSTMENT (TIRE MOUNTED).........................282 STEERING CYLINDERS AND TIE ROD......................................284 REMOVAL.........................................................284 INSTALLATION....................................................284 BEARING REPLACEMENT.............................................284 TOE-IN ADJUSTMENT...................................................286 REAR AXLE HOUSING ATTACHMENT (G04010)...................................288 PIVOT PIN...........................................................288 REMOVAL.........................................................288 INSTALLATION....................................................288 DISASSEMBLY.....................................................289 ASSEMBLY........................................................289 ANTI-SWAY BAR.......................................................291 REMOVAL.........................................................291 INSTALLATION....................................................291 DISASSEMBLY.....................................................291 CLEANING AND INSPECTION.........................................291 ASSEMBLY........................................................291 REAR AXLE HOUSING (G05004)..............................................292 REAR AXLE HOUSING...................................................292 REMOVAL.........................................................292 INSTALLATION....................................................292 WHEEL MOTOR.........................................................292 REMOVAL.........................................................292 CLEANING AND INSPECTION.........................................293 INSTALLATION....................................................293 H. HYDRAIR II SUSPENSIONS...................................................294 FRONT SUSPENSION........................................................296 REMOVAL.............................................................296 INSTALLATION........................................................297 DISASSEMBLY.....................................................300 ASSEMBLY (BEARING RETAINER ONLY)................................302 ASSEMBLY (COMPLETE).............................................302 SUSPENSION PRESSURE TEST............................................303 REAR SUSPENSION.........................................................304 REMOVAL.............................................................305 INSTALLATION........................................................307 DISASSEMBLY..................................................... 0 ASSEMBLY........................................................ 0 SUSPENSION PRESSURE TEST............................................310 OILING AND CHARGING PROCEDURES..........................................312 GENERAL.............................................................312 EQUIPMENT LIST......................................................312 FRONT SUSPENSION....................................................314 FRONT SUSPENSION OILING.........................................314 FRONT SUSPENSION NITROGEN CHARGING..............................315 REAR SUSPENSION.....................................................316 REAR SUSPENSION OILING..........................................316 REAR SUSPENSION NITROGEN CHARGING...............................317 OIL AND NITROGEN SPECIFICATIONS.........................................319 J. BRAKE CIRCUIT............................................................320 BRAKE CIRCUIT...........................................................322 SERVICE BRAKE CIRCUIT OPERATION.....................................322 SECONDARY BRAKING AND AUTOMATIC APPLY...............................324 PARKING BRAKE CIRCUIT...............................................324 BRAKE LOCK CIRCUIT..................................................325 WARNING CIRCUIT.....................................................325 BRAKE VALVE CUT-AWAY................................................326 BRAKE CIRCUIT COMPONENT SERVICE.........................................328 BRAKE VALVE.........................................................328 REMOVAL.........................................................328 INSTALLATION....................................................330 DISASSEMBLY.....................................................332 CLEANING AND INSPECTION.........................................334 ASSEMBLY........................................................338 BENCH TEST AND ADJUSTMENT.......................................338 INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE....342 INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE.......344 HYDRAULIC BRAKE ACCUMULATORS........................................345 REMOVAL.........................................................345 INSTALLATION....................................................345 DISASSEMBLY.....................................................345 CLEANING AND INSPECTION.........................................346 ASSEMBLY........................................................347 CHARGING PROCEDURE..............................................348 BRAKE CIRCUIT CHECKOUT PROCEDURE........................................350 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...........................356 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET...................360 FRONT BRAKES (ROCKWELL).................................................362 BRAKE CALIPER.......................................................362 BRAKE LINING........................................................366 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE.......................367 BRAKE BLEEDING PROCEDURE............................................368 REAR BRAKES (ROCKWELL)..................................................370 BRAKE CALIPER, DISC AND PARKING BRAKE...............................370 CALIPER PISTON ASSEMBLY.............................................375 BENCH TEST..........................................................376 BRAKE LINING........................................................382 BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE........................385 BRAKE BLEEDING PROCEDURE............................................387 PARKING BRAKE (ROCKWELL)................................................388 CALIPER.............................................................388 REMOVAL.........................................................388 INSTALLATION....................................................389 PARKING BRAKE ADJUSTMENT (SCL 70)...............................389 PARKING BRAKE ADJUSTMENT................................................389 PARK BRAKE CALIPER DISASSEMBLY......................................391 CLEANING AN INSPECTION..............................................391 PARK BRAKE CALIPER ASSEMBLY.........................................392 PARK BRAKE LINING.......................................................393 REPLACEMENT.........................................................393 CONDITIONING (BURNISHING PROCEDURE).................................393 BRAKE BLEEDING PROCEDURE................................................393 L. HYDRAULIC SYSTEM.........................................................394 HYDRAULIC SYSTEM........................................................396 HOIST CIRCUIT OPERATION.............................................396 STEERING CIRCUIT OPERATION..........................................398 HYDRAULIC COMPONENT REPAIR..............................................402 HOIST PUMP..........................................................402 REMOVAL.........................................................402 INSTALLATION....................................................403 DISASSEMBLY.....................................................404 INSPECTION......................................................406 ASSEMBLY........................................................407 TROUBLESHOOTING GUIDE...........................................411 HYDRAULIC TANK..........................................................412 FILLING INSTRUCTIONS................................................412 REMOVAL.............................................................413 INSTALLATION........................................................413 STRAINER AND DIFFUSER...............................................413 STEERING CIRCUIT........................................................416 STEERING CIRCUIT OPERATION..........................................416 COMPONENT DESCRIPTION...............................................417 STEERING CONTROL VALVE..........................................417 UNLOADER VALVE..................................................417 BLEED DOWN MANIFOLD VALVE.......................................418 FLOW AMPLIFIER..................................................422 STEERING PUMP...................................................431 ACCUMULATORS....................................................431 STEERING CONTROL VALVE..............................................432 REMOVAL.........................................................432 INSTALLATION....................................................432 REBUILD PROCEDURE...............................................433 DISASSEMBLY.................................................433 CLEANING AND INSPECTION.....................................434 ASSEMBLY....................................................436 STEERING PUMP...................................................439 REMOVAL.....................................................439 INSTALLATION................................................439 DISASSEMBLY.................................................441 INSPECTION..................................................441 ASSEMBLY....................................................441 STEERING CIRCUIT COMPONENT REPAIR................................... 0 BLEEDDOWN MANIFOLD VALVE........................................ 0 STEERING ACCUMULATORS........................................... 0 STEERING ACCUMULATORS CHARGING PROCEDURE........................ 0 FLOW AMPLIFIER.................................................. 0 STEERING CYLINDERS.............................................. 0 HOIST CIRCUIT.......................................................458 HOIST CIRCUIT OPERATION.........................................458 COMPONENT DESCRIPTION...........................................459 HOIST CIRCUIT COMPONENT REPAIR......................................472 HOIST VALVE.....................................................472 HOIST PILOT VALVE...............................................480 HOIST-UP LIMIT SOLENOID VALVE...................................483 HOIST CYLINDERS.................................................483 HYDRAULIC SYSTEM FILTERS............................................492 HOIST CIRCUIT FILTER............................................492 STEERING CIRCUIT FILTER.........................................494 HYDRAULIC CHECKOUT PROCEDURES.......................................498 STEERING CIRCUIT TEST PROCEDURE.................................498 COMPONENT LEAKAGE TEST......................................500 TROUBLESHOOTING CHART...........................................502 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURES....................505 POWER UP RELIEF PRESSURE TEST...............................505 POWER DOWN RELIEF PRESSURE TEST.............................506 HOIST COUNTERBALANCE VALVE ADJUSTMENT.......................507 DISABLED TRUCK DUMPING PROCEDURE................................508 HYDRAULIC SYSTEM FLUSHING PROCEDURE.............................509 M. OPTIONS AND SPECIAL TOOLS................................................512 FIRE CONTROL SYSTEMS....................................................514 ANSUL FIRE CONTROL PNEUMATIC SYSTEM.................................514 ANSUL FIRE CONTROL ELECTRIC SYSTEM..................................520 ANSUL FIRE CONTROL SYSTEM MANUAL....................................530 OPERATION.......................................................530 INSPECTION AND MAINTENANCE......................................530 RECHARGING PROCEDURES...........................................531 WIGGINS QUICK FILL FUEL SYSTEM..........................................532 TANK BREATHER VALVE.................................................533 FUEL RECEIVER.......................................................532 FAN DRIVE CLUTCH - HYDRAULIC ACTUATED...................................536 GENERAL DESCRIPTION.................................................536 MAINTENANCE.........................................................539 TROUBLESHOOTING.....................................................541 FIELD CHECK DIAGNOSIS...............................................542 THERMAL SENSOR AND SOLENOID VALVE...............................543 TROUBLESHOOTING CHART...............................................546 DISASSEMBLY.........................................................550 REASSEMBLY..........................................................557 INSPECTION OF PARTS.................................................568 REBUILD TOOLS.......................................................573 ENGINE COOLANT HEATER SYSTEM - HOT START - 220 VOLT.....................574 HEATING ELEMENT.....................................................574 THERMOSTAT..........................................................575 ENGINE OIL HEATERS - HOT START - 220 VOLT...............................576 TROUBLESHOOTING..................................................... 0 HEATING ELEMENT.....................................................576 ENGINE AND COOLANT HEATERS - 440 VOLT...................................578 TROUBLESHOOTING.....................................................579 COOLANT HEATING ELEMENT.............................................580 OIL HEATING ELEMENT.................................................581 Untitled................................................................668 SPECIAL TOOL GROUP......................................................584 HEATER / AIR CONDITIONING SYSTEM........................................592 ENVIRONMENTAL IMPACT................................................592 OPERATOR CAB CONDITIONING...........................................593 PRINCIPLES OF REFRIGERATION.........................................593 MAJOR SYSTEM COMPONENTS.............................................595 SYSTEM SERVICING....................................................599 EVACUATING THE SYSTEM...............................................616 SYSTEM TROUBLESHOOTING..............................................618 24 VDC ELECTRIC SUPPLY SYSTEM...........................................628 ELECTRICAL SYSTEM DESCRIPTION.......................................628 BATTERY - MAINTENANCE AND SERVICE...................................628 BATTERY CHARGING SYSTEM.............................................630 GENERAL DESCRIPTION.............................................630 TROUBLESHOOTING PROCEDURES......................................630 NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL..............................638 DIMENSIONS..........................................................639 SPECIFICATIONS......................................................640 SERVICE PARTS LIST..................................................641 EXPLODED VIEW.......................................................642 ON VEHICLE TEST.....................................................643 BENCH TEST..........................................................645 STATIC TESTS........................................................646 ALTERNATOR DISASSEMBLY..............................................649 ALTERNATOR ASSEMBLY.................................................654 SERVICE TOOL INSTRUCTIONS...........................................663 FUEL - WATER SEPARATOR..................................................666 INSTALLATION........................................................666 OPERATION...........................................................666 FILTER SERVICE......................................................667 PAYLOAD METER III.......................................................668 OPERATION SECTION...................................................671 INTRODUCTION........................................................671 DATA SUMMARY........................................................671 DATA GATHERING......................................................671 COMPONENT DESCRIPTION...............................................672 SYSTEM DIAGRAM..................................................672 SUSPENSION PRESSURE SENSORS.....................................672 INCLINOMETER....................................................672 OPERATOR DISPLAY................................................672 OPERATOR SWITCH.................................................673 SPEED INPUT.....................................................673 BODY-UP SWITCH..................................................673 BRAKE LOCK SWITCH...............................................673 PAYLOAD METER...................................................673 COMMUNICATIONS PORT.............................................673 KEYSWITCH INPUT.................................................674 PAYLOAD METER POWER.............................................674 LOAD LIGHTS.....................................................674 WIRING AND TERMINATION..........................................675 TCI OUTPUTS.....................................................675 OPERATOR'S DISPLAY AND SWITCH.......................................676 READING THE SPEEDOMETER.........................................676 READING THE LOAD DISPLAY........................................676 USING THE OPERATOR ID...........................................676 USING THE LOAD AND TON COUNTER..................................676 TOTAL TON COUNTER...........................................668 TOTAL LOAD COUNTER..........................................677 CLEARING THE COUNTERS.......................................677 VIEWING LIVE SENSOR DATA........................................677 OTHER DISPLAY MESSAGES..........................................677 PAYLOAD OPERATION AND CALCULATION...................................678 DESCRIPTION OF HAUL CYCLE STATES................................678 STAGES OF A TYPICAL HAUL CYCLE..............................678 HAUL CYCLE DESCRIPTION......................................678 LOAD CALCULATION................................................679 CARRY BACK......................................................679 MEASUREMENT ACCURACY............................................679 SOURCES FOR PAYLOAD ERROR.......................................679 PAYLOAD ERROR...............................................679 LOADING CONDITIONS..........................................680 PRESSURE SENSORS............................................680 SWINGLOADS..................................................680 SPEED AND DISTANCE..........................................680 HAUL CYCLE DATA.....................................................681 HAUL CYCLE DATA.................................................681 HAUL CYCLE WARNING FLAGS........................................682 ALARM RECORDS...................................................683 FRAME TORQUE DATA...............................................683 SPRUNG WEIGHT DATA..............................................684 MAXIMUM SPEED DATA..............................................684 PC SOFTWARE OVERVIEW................................................684 PC OVERVIEW.....................................................684 SYSTEM CONFIGURATION............................................684 INSTALLING THE PAYLOAD METER III SOFTWARE.......................684 DOWNLOADING DATA....................................................685 PLM III SYSTEM CONFIGURATION........................................686 STARTING COMMUNICATIONS.........................................686 DISPLAYED PAYLOAD UNITS.....................................686 TIME UNITS..................................................686 CONNECTION MENU.................................................686 CONNECTING TO THE PAYLOAD METER.................................687 CONFIGURE THE PAYLOAD METER.....................................687 SETTING THE DATE AND TIME...................................687 SETTING THE TRUCK TYPE......................................688 SETTING THE GAUGE DISPLAY UNITS.............................688 SETTING THE FRAME SERIAL NUMBER.............................688 SETTING THE TRUCK NUMBER....................................688 SETTING THE KOMATSU DISTRIBUTOR.............................688 SETTING THE KOMATUS CUSTOMER................................688 CLEAN TRUCK TARE................................................689 INCLINOMETER CALIBRATION........................................689 DATA ANALYSIS.......................................................690 CREATING A QUERY................................................690 SORTING ON TRUCK UNIT NUMBER................................690 SORTING ON TRUCK TYPE.......................................690 SORTING ON DATE RANGE.......................................691 SORTING ON TIME RANGE.......................................691 PAYLOAD DETAIL SCREEN...........................................692 CREATING REPORTS................................................692 SUMMARY - ONE PAGE REPORT...................................693 DETAILED - MULTI PAGE REPORT................................693 CREATING GRAPHS.................................................694 EXPORTING DATA..................................................694 CSV EXPORT..................................................694 COMPRESSED..................................................695 IMPORTING DATA..................................................696 DELETING HAUL CYCLE RECORDS.....................................696 VIEWING ALARMS..................................................697 DELETING HAUL CYCLE RECORDS.....................................697 VIEWING ALARMS..................................................697 DELETING ALARM RECORDS..........................................697 TROUBLESHOOTING SECTION.............................................698 TROUBLESHOOTING.................................................698 VIEWING ACTIVE ALARMS...........................................698 REAL-TIME DATA DISPLAY..........................................698 TESTING THE PAYLOAD LIGHTS......................................698 CREATING LOG FILES OF INPUTS....................................699 DAILY INSPECTIONS...............................................699 PERIODIC MAINTENANCE............................................699 ABNORMAL DISPLAYS AT POWER-UP...................................700 NO PAYLOAD DISPLAY WHEN KEYSWITCH IS TURNED ON..................701 NO DISPLAY ON SPEEDOMETER.......................................702 NO DISPLAY ON OPERATOR DISPLAY..................................702 NO COMMUNICATIONS WITH PC.......................................703 LOAD LIGHTS DON'T LIGHT DURING LOADING..........................704 LOAD LIGHTS REMAIN ON...........................................705 LOAD LIGHTS REMAIN ON DURING DUMPING............................705 DISPLAY DOESN'T CLEAR WHEN THE LOAD IS DUMPED..................705 CALIBRATION PROBLEMS............................................706 ALARM 1 - LEFT FRONT PRESSURE HIGH..............................707 ALARM 2 - LEFT FRONT PRESSURE LOW...............................707 TROUBLESHOOT WIRING TO LEFT FRONT SUSPENSION....................707 ALARM 3 - RIGHT FRONT PRESSURE HIGH.............................708 ALARM 4 - RIGHT FRONT PRESSURE LOW..............................708 TROUBLESHOOT WIRING TO RIGHT FRONT SUSPENSION...................708 ALARM 5 - LEFT REAR PRESSURE HIGH...............................709 ALARM 6 - LEFT REAR PRESSURE LOW................................709 TROUBLESHOOT WIRING TO LEFT REAR SUSPENSION.....................709 ALARM 7 - RIGHT REAR PRESSURE HIGH..............................710 ALARM 8 - RIGHT REAR PRESSURE LOW...............................710 TROUBLESHOOT WIRING TO RIGHT REAR SUSPENSION....................710 ALARM 9 - INCLINOMETER HIGH.....................................711 ALARM 10 - INCLINOMETER LOW.....................................711 TROUBLESHOOTING INCLINOMETER WIRING.............................711 ALARM 13 - BODY UP INPUT FAILURE................................712 ALARM 15 - MEMORY WRITE FAILURE.................................713 ALARM 16 - MEMORY READ FAILURE..................................713 ALARM 24 - SYSTEM KEY-ON STATUS.................................713 OPERATOR SWITCH DOESN'T WORK....................................714 ALARM 26 - USER SWITCH FAULT - SELECT...........................714 ALARM 27 - USER SWITCH FAULT - SET..............................714 CONNECTOR MAP...................................................715 CONNECTORS......................................................716 CHECKOUT PROCEDURE SECTION..........................................718 PLM III CHECKOUT PROCEDURE......................................718 GENERAL DESCRIPTION.........................................718 TOOLS REQUIRED..............................................718 CHECKOUT PROCEDURE..........................................718 PLM III CHECKOUT PROCEDURE CONFIRMATION.........................722 1.1 FLASHBURN PROGRAMMING - GENERAL INSTRUCTIONS............722 CONFIRMATION CHECKLIST......................................724 COMPONENTS AND SCHEMATICS SECTION...................................725 PAYLOAD METER III COMPONENTS....................................725 PRESSURE SENSOR.............................................725 CONTROLLER..................................................725 SPEEDOMETER.................................................725 N. OPERATOR'S CAB...........................................................726 TRUCK CAB...............................................................728 DESCRIPTION.........................................................728 REMOVAL.........................................................729 INSTALLATION....................................................730 CAB DOOR............................................................731 REMOVAL.........................................................731 INSTALLATION....................................................731 DOOR ADJUSTMENT.................................................731 DOOR GLASS REPLACEMENT..........................................734 DOOR HANDLE OR LATCH REPLACEMENT................................738 DOOR AND DOOR HINGE SEAL REPLACEMENT............................739 GLASS REPLACEMENT...................................................740 ADHESIVE BONDED WINDOWS.........................................740 WINDSHIELD AND REAR GLASS REPLACEMENT...........................740 CAB COMPONENTS.......................................................... 0 WINDSHIELD WIPER....................................................744 WINDSHIELD WASHER...................................................746 OPERATOR COMFORT........................................................748 OPERATOR SEAT.......................................................748 ADJUSTMENT......................................................748 REMOVAL.........................................................748 INSTALLATION....................................................748 HEATER / AIR CONDITIONER................................................749 OPERATION...........................................................749 HEATER COMPONENTS.......................................................750 CIRCUIT BREAKERS....................................................750 HEATER CONTROL COMPONENTS...........................................750 HEATER CORE.........................................................751 FAN MOTOR AND SPEED CONTROL.........................................751 ACTUATORS...........................................................751 FILTER..............................................................751 OPERATOR CONTROLS.......................................................754 STEERING COLUMN.....................................................755 REMOVAL.........................................................755 INSTALLATION....................................................756 PEDAL CONTROLS......................................................757 THROTTLE PEDAL..................................................757 SERVICE BRAKE PEDAL.............................................757 DUAL FUNCTION / SINGLE BRAKE PEDAL..............................757 DYNAMIC RETARDING PEDAL.........................................757 CONSOLE CONTROLS........................................................759 INSTRUMENT PANEL........................................................763 INDICATOR LIGHTS........................................................769 CENTRY FUEL SYSTEM......................................................775 DIAGNOSTICS......................................................... 0 DETERMINING FAULT CODES............................................. 0 P. LUBRICATION AND SERVICE..................................................778 LUBRICATION AND SERVICE.................................................780 SERVICE CAPACITIES..................................................780 HYDRAULIC TANK SERVICE..............................................780 HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS)....................... 0 COOLANT LEVEL CHECK.................................................781 RADIATOR FILLING PROCEDURE..........................................781 COOLING SYSTEM RECOMMENDATIONS......................................781 LUBRICATION CHART...................................................782 10 HOURS........................................................783 50 HOURS........................................................785 100 HOURS.......................................................786 250 HOURS.......................................................787 500 HOURS.......................................................789 1000 HOURS......................................................790 5000 HOURS......................................................791 LINCOLN AUTOMATIC LUBRICATION SYSTEM....................................792 GENERAL DESCRIPTION.................................................792 SYSTEM COMPONENTS...................................................794 SYSTEM OPERATION....................................................795 GENERAL INSTRUCTIONS................................................798 SYSTEM PRIMING..................................................798 LUBRICANT PUMP..................................................798 FILTER AND RESERVOIR............................................799 INJECTORS.......................................................800 SYSTEM CHECK-OUT....................................................801 24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT...................801 PUMP REBUILD........................................................802 DISASSEMBLY.....................................................802 CLEANING AND INSPECTION.........................................802 ASSEMBLY........................................................804 PREVENTATIVE MAINTENANCE PROCEDURE..................................808 MOTORIZED WHEEL MAINTENANCE SCHEDULE....................................810 Q. ALPHABETICAL INDEX.......................................................814 R. SYSTEM SCHEMATICS........................................................818 HYDRAULIC BRAKE SYSTEM SCHEMATIC........................................820 HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE)................................821 ELECTRICAL SCHEMATIC....................................................822 PAYLOAD METER III ELECTRICAL SCHEMATIC..................................850
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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