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Komatsu 730E Dump Truck With Trolley Assist Service Repair Manual SN A30225 and A30226 – PDF DOWNLOAD
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Komatsu 730E Dump Truck With Trolley Assist Service Repair Manual
Book Code : CEBM011500
SERIAL NUMBERS : A30225 and A30226
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Description
Komatsu 730E Dump Truck With Trolley Assist Service Repair Manual
FILE DETAILS:
Komatsu 730E Dump Truck With Trolley Assist Service Repair Manual
Model Specification: KOMATSU 730E DUMP TRUCK with TROLLEY ASSIST
Language: English
File Format: PDF
Total Pages: 903
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU 730E DUMP TRUCK WITH TROLLEY ASSIST SERVICE REPAIR MANUAL SN A30225 AND A30226 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 730E Dump Truck With Trolley Assist Service Repair 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 ±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 “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 Service Repair Manual
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 PROCEDURE.........................................100 COOLING SYSTEM TROUBLESHOOTING..................................101 POWER TRAIN.............................................................102 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.......................102 REMOVAL.........................................................102 ENGINE / ALTERNATOR MATING..........................................104 ALTERNATOR MEASUREMENT..........................................104 ENGINE END PLAY MEASUREMENT.....................................105 DETERMINING SHIM REQUIREMENTS...................................105 INSTALLATION....................................................106 ENGINE..............................................................108 REMOVAL.........................................................108 INSTALLATION....................................................108 AIR CLEANERS............................................................110 FILTER ELEMENT REPLACEMENT..........................................110 MAIN FILTER ELEMENT CLEANING........................................112 PRECLEANER SECTION..................................................113 D. ELECTRIC SYSTEM (24 VDC, NON-PROPULSION).................................116 24 VDC ELECTRIC SUPPLY SYSTEM...........................................118 ELECTRICAL SYSTEM DESCRIPTION.......................................118 BATTERY - MAINTENANCE AND SERVICE...................................118 ELECTRIC START SYSTEM...............................................120 OPERATION.......................................................120 REMOVAL.....................................................120 INSTALLATION................................................120 CRANKING MOTOR TROUBLESHOOTING..................................121 DISASSEMBLY.....................................................122 SOLENOID CHECKS.................................................125 ASSEMBLY........................................................126 ENGINE PRELUB STARTER SYSTEM........................................129 OPERATION.......................................................129 TROUBLESHOOTING.................................................131 24 VDC ELECTRICAL SYSTEM COMPONENTS.....................................134 PASSENGER SEAT BASE COMPARTMENT.....................................134 TAIL LIGHT RESISTOR DIODE ASSEMBLIES............................134 5 MINUTE IDLE TIMER COMPONENTS..................................134 ALARM INDICATING DEVICE (A.I.D. SYSTEM..........................137 BODY UP SWITCH......................................................140 HOIST LIMIT SWITCH..................................................140 24 VDC RELAY AND DIODE BOARDS.......................................141 DESCRIPTION.....................................................141 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 1...................................................146 CIRCUIT BREAKER CHART...........................................147 E. ELECTRIC PROPULSION AND CONTROL..........................................148 ELECTRICAL PROPULSION COMPONENTS........................................150 GENERAL SYSTEM DESCRIPTION..........................................150 CONTROL SYSTEM......................................................150 FL275 PANEL.........................................................152 COMPUTER DESCRIPTION............................................154 SOFTWARE........................................................154 2-DIGIT DISPLAY PANEL...............................................157 EVENTS..........................................................157 FRAMES..........................................................158 WINDOWS.........................................................158 EVENT CODE DESCRIPTIONS (TABLE I)...........................166 SUBCODE DESCRIPTIONS (TABLE II).............................167 PORTABLE TEST UNIT (PTU)............................................170 DESCRIPTION.....................................................170 SOFTWARE INSTALLATION PREPARATION...............................171 THE MAIN MENU...............................................173 PTU SOFTWARE MENU TREE......................................174 CONFIGURATION (CFG) FILE CONVERSION.........................175 STATEX CONFIGURATION FILES......................................179 PROGRAMMING THE TRUCK...........................................190 PTU HOOKUP..................................................190 DOWNLOAD CONFIGURATION FILES................................192 EVENT DATA......................................................194 STATISTICAL DATA................................................196 STATISTICAL DATA CODES - COUNTERS (TABLE III)...............198 STATISTICAL DATA CODES - PROFILES (TABLE IV)................203 TRUCK SPECIFIC INFORMATION......................................207 TEMPORARY TRUCK SETTINGS........................................208 MISCELLANEOUS SOFTWARE FEATURES.................................209 SAVING DATA.................................................209 PTU ABBREVIATIONS...........................................210 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..........................211 ALTERNATOR..........................................................211 ELECTRIC WHEEL MOTORS...............................................211 RETARDING GRIDS.....................................................211 ELECTRONIC ACCELERATOR AND RETARD CONTROL...........................211 COOLING BLOWER WARNING SYSTEM.......................................213 ELECTRICAL CONTROL CABINET..........................................214 STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS..................219 ELECTRICAL CHECKOUT PROCEDURE...........................................222 G. DRIVE AXLE, SPINDLES AND WHEELS..........................................274 TIRES AND RIMS (G02004).................................................276 FRONT TIRES AND RIMS................................................276 REMOVAL.........................................................276 INSTALLATION....................................................277 REAR TIRES AND RIMS.................................................278 REMOVAL.........................................................278 INSTALLATION....................................................279 RIM.................................................................280 TIRE REMOVAL....................................................280 TIRE INSTALLATION...............................................281 FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)...........................284 WHEEL HUB AND SPINDLE ASSEMBLY......................................284 REMOVAL.........................................................284 INSTALLATION....................................................286 DISASSEMBLY.....................................................286 CLEANING AND INSPECTION.........................................287 ASSEMBLY........................................................287 WHEEL BEARING ADJUSTMENT (TIRE REMOVED).........................290 WHEEL BEARING ADJUSTMENT (TIRE MOUNTED).........................290 STEERING CYLINDERS AND TIE ROD......................................292 REMOVAL.........................................................293 INSTALLATION....................................................294 BEARING REPLACEMENT.............................................294 TOE-IN ADJUSTMENT...................................................295 REAR AXLE HOUSING ATTACHMENT (G04010)...................................296 PIVOT PIN...........................................................296 REMOVAL.........................................................296 INSTALLATION....................................................296 DISASSEMBLY.....................................................297 ASSEMBLY........................................................297 ANTI-SWAY BAR.......................................................299 REMOVAL.........................................................299 INSTALLATION....................................................299 DISASSEMBLY.....................................................299 CLEANING AND INSPECTION.........................................299 ASSEMBLY........................................................299 REAR AXLE HOUSING (G05004)..............................................300 REAR AXLE HOUSING...................................................300 REMOVAL.........................................................300 INSTALLATION....................................................300 WHEEL MOTOR.........................................................300 REMOVAL.........................................................300 CLEANING AND INSPECTION.........................................301 INSTALLATION....................................................301 H. HYDRAIR II SUSPENSIONS...................................................302 FRONT SUSPENSION........................................................304 REMOVAL.............................................................304 INSTALLATION........................................................305 DISASSEMBLY.....................................................308 ASSEMBLY (BEARING RETAINER ONLY)................................310 ASSEMBLY (COMPLETE).............................................310 SUSPENSION PRESSURE TEST............................................311 REAR SUSPENSION.........................................................312 REMOVAL.............................................................313 INSTALLATION........................................................315 DISASSEMBLY.....................................................315 ASSEMBLY........................................................316 SUSPENSION PRESSURE TEST............................................318 OILING AND CHARGING PROCEDURES..........................................320 GENERAL.............................................................320 EQUIPMENT LIST......................................................320 FRONT SUSPENSION....................................................322 FRONT SUSPENSION OILING.........................................322 FRONT SUSPENSION NITROGEN CHARGING..............................323 REAR SUSPENSION.....................................................324 REAR SUSPENSION OILING..........................................324 REAR SUSPENSION NITROGEN CHARGING...............................326 OIL AND NITROGEN SPECIFICATIONS.........................................327 J. BRAKE CIRCUIT............................................................328 BRAKE CIRCUIT...........................................................330 SERVICE BRAKE CIRCUIT OPERATION.....................................330 SECONDARY BRAKING AND AUTOMATIC APPLY...............................332 PARKING BRAKE CIRCUIT...............................................332 BRAKE LOCK CIRCUIT..................................................333 WARNING CIRCUIT.....................................................333 BRAKE VALVE CUT-AWAY................................................334 BRAKE CIRCUIT COMPONENT SERVICE.........................................336 BRAKE VALVE.........................................................336 REMOVAL.........................................................336 INSTALLATION....................................................338 DISASSEMBLY.....................................................340 CLEANING AND INSPECTION.........................................342 ASSEMBLY........................................................342 BENCH TEST AND ADJUSTMENT.......................................346 INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE....350 INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE.......352 HYDRAULIC BRAKE ACCUMULATORS........................................353 REMOVAL.........................................................353 INSTALLATION....................................................353 DISASSEMBLY.....................................................353 CLEANING AND INSPECTION.........................................355 ASSEMBLY........................................................355 CHARGING PROCEDURE..............................................356 BRAKE CIRCUIT CHECKOUT PROCEDURE........................................358 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...........................364 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET...................368 FRONT BRAKES (ROCKWELL).................................................370 BRAKE CALIPER.......................................................370 BRAKE LINING........................................................374 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE.......................375 BRAKE BLEEDING PROCEDURE............................................376 REAR BRAKES (ROCKWELL)..................................................378 BRAKE CALIPER, DISC AND PARKING BRAKE...............................378 CALIPER PISTON ASSEMBLY.............................................383 BENCH TEST..........................................................389 BRAKE LINING........................................................390 BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE........................394 BRAKE BLEEDING PROCEDURE............................................395 PARKING BRAKE (ROCKWELL)................................................396 PARK BRAKE CALIPER..................................................396 REMOVAL.........................................................396 INSTALLATION....................................................397 PARKING BRAKE ADJUSTMENT .......................................397 PARKING BRAKE ADJUSTMENT................................................397 PARK BRAKE CALIPER DISASSEMBLY......................................399 CLEANING AN INSPECTION..............................................399 PARK BRAKE CALIPER ASSEMBLY.........................................400 PARK BRAKE LINING.......................................................401 REPLACEMENT......................................................... 0 CONDITIONING (BURNISHING PROCEDURE)................................. 0 BRAKE BLEEDING PROCEDURE................................................401 L. HYDRAULIC SYSTEM.........................................................402 HYDRAULIC SYSTEM........................................................406 HOIST CIRCUIT OPERATION.............................................406 STEERING CIRCUIT OPERATION..........................................407 AXLE BLOWER OPERATION...............................................409 HYDRAULIC COMPONENT REPAIR..............................................412 HOIST PUMP..........................................................412 REMOVAL.........................................................412 INSTALLATION....................................................413 DISASSEMBLY.....................................................414 INSPECTION......................................................416 ASSEMBLY........................................................417 TROUBLESHOOTING GUIDE...........................................421 PISTON PUMP.............................................................422 REMOVAL.............................................................422 INSTALLATION........................................................422 DISASSEMBLY.........................................................424 INSPECTION..........................................................430 ASSEMBLY............................................................432 AXLE BLOWER HYDRAULIC MOTOR.............................................436 REMOVAL.............................................................436 INSTALLATION........................................................436 REAR AXLE BLOWER HOUSING............................................436 DISASSEMBLY.....................................................436 ASSEMBLY........................................................436 DISASSEMBLY.........................................................438 INSPECTION..........................................................440 ASSEMBLY............................................................441 TROUBLESHOOTING.....................................................442 HAND WHEEL CONTROL..................................................443 DISASSEMBLY.....................................................443 ASSEMBLY........................................................443 HYDRAULIC TANK..........................................................445 FILLING INSTRUCTIONS................................................445 REMOVAL.............................................................446 INSTALLATION........................................................446 STRAINER AND DIFFUSER...............................................446 STEERING CIRCUIT........................................................448 STEERING CIRCUIT OPERATION..........................................448 COMPONENT DESCRIPTION...............................................449 STEERING CONTROL VALVE..........................................449 UNLOADER VALVE..................................................449 BLEED DOWN MANIFOLD VALVE.......................................450 FLOW AMPLIFIER..................................................454 STEERING PUMP...................................................463 ACCUMULATORS....................................................463 STEERING CONTROL VALVE..............................................464 REMOVAL.........................................................464 INSTALLATION....................................................464 REBUILD PROCEDURE...............................................465 DISASSEMBLY.................................................465 CLEANING AND INSPECTION.....................................466 ASSEMBLY....................................................468 STEERING PUMP...................................................471 REMOVAL.....................................................471 INSTALLATION................................................471 DISASSEMBLY.................................................473 INSPECTION..................................................473 ASSEMBLY....................................................473 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.......................................................490 HOIST CIRCUIT OPERATION.........................................490 COMPONENT DESCRIPTION...........................................491 HOIST CIRCUIT COMPONENT REPAIR......................................504 HOIST VALVE.....................................................504 HOIST PILOT VALVE...............................................512 HOIST-UP LIMIT SOLENOID VALVE...................................515 HOIST CYLINDERS.................................................515 HYDRAULIC SYSTEM FILTERS............................................524 HOIST CIRCUIT FILTER............................................524 STEERING CIRCUIT FILTER.........................................526 HYDRAULIC CHECKOUT PROCEDURES.......................................530 STEERING CIRCUIT TEST PROCEDURE.................................530 COMPONENT LEAKAGE TEST......................................532 TROUBLESHOOTING CHART.......................................534 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURES....................537 POWER UP RELIEF PRESSURE TEST...............................537 POWER DOWN RELIEF PRESSURE TEST.............................538 HOIST COUNTERBALANCE VALVE ADJUSTMENT.......................539 DISABLED TRUCK DUMPING PROCEDURE................................541 HYDRAULIC SYSTEM FLUSHING PROCEDURE.............................542 HYDRAULIC SYSTEM TEST PROCEDURE.................................545 M. OPTIONS AND SPECIAL TOOLS................................................548 FIRE CONTROL SYSTEMS....................................................550 ANSUL FIRE CONTROL PNEUMATIC SYSTEM.................................550 ANSUL FIRE CONTROL ELECTRIC SYSTEM..................................561 ANSUL FIRE CONTROL SYSTEM MANUAL....................................566 OPERATION.......................................................566 INSPECTION AND MAINTENANCE......................................566 RECHARGING PROCEDURES...........................................567 ALTERNATOR AND WHEEL MOTOR COOLING AIR FILTER SYSTEM....................568 SYSTEM ADJUSTMENT...................................................568 PUMP................................................................568 BLOWER DRIVE MOTOR..................................................571 BLOWER BEARING REPAIR...............................................574 AIR CLEANER.........................................................575 WIGGINS QUICK FILL FUEL SYSTEM..........................................576 TANK BREATHER VALVE.................................................577 FUEL RECEIVER.......................................................578 FAN DRIVE CLUTCH - HYDRAULIC ACTUATED...................................580 GENERAL DESCRIPTION.................................................580 MAINTENANCE.........................................................583 TROUBLESHOOTING.....................................................585 FIELD CHECK DIAGNOSIS...............................................586 THERMAL SENSOR AND SOLENOID VALVE...............................587 TROUBLESHOOTING CHART...............................................590 DISASSEMBLY.........................................................594 REASSEMBLY..........................................................601 INSPECTION OF PARTS.................................................612 REBUILD TOOLS.......................................................617 ENGINE COOLANT HEATER SYSTEM - HOT START - 220 VOLT.....................618 HEATING ELEMENT.....................................................618 THERMOSTAT..........................................................619 ENGINE OIL HEATERS - HOT START - 220 VOLT...............................620 TROUBLESHOOTING.....................................................620 HEATING ELEMENT.....................................................620 ENGINE AND COOLANT HEATERS - 440 VOLT...................................622 TROUBLESHOOTING.....................................................623 COOLANT HEATING ELEMENT.............................................624 OIL HEATING ELEMENT.................................................625 SPECIAL TOOL GROUP......................................................628 HEATER / AIR CONDITIONING SYSTEM........................................636 ENVIRONMENTAL IMPACT................................................636 OPERATOR CAB CONDITIONING...........................................637 PRINCIPLES OF REFRIGERATION.........................................637 MAJOR SYSTEM COMPONENTS.............................................639 SYSTEM SERVICING....................................................643 EVACUATING THE SYSTEM...............................................660 SYSTEM TROUBLESHOOTING..............................................662 24 VDC ELECTRIC SUPPLY SYSTEM...........................................672 ELECTRICAL SYSTEM DESCRIPTION.......................................672 BATTERY - MAINTENANCE AND SERVICE...................................672 BATTERY CHARGING SYSTEM.............................................674 GENERAL DESCRIPTION.............................................674 TROUBLESHOOTING PROCEDURES......................................674 NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL..............................682 DIMENSIONS..........................................................683 SPECIFICATIONS......................................................684 SERVICE PARTS LIST..................................................685 EXPLODED VIEW.......................................................686 ON VEHICLE TEST.....................................................688 BENCH TEST..........................................................689 STATIC TESTS........................................................690 ALTERNATOR DISASSEMBLY..............................................693 ALTERNATOR ASSEMBLY.................................................698 SERVICE TOOL INSTRUCTIONS...........................................707 FUEL - WATER SEPARATOR..................................................710 INSTALLATION........................................................710 OPERATION...........................................................710 FILTER SERVICE......................................................711 PAYLOAD METER III.......................................................712 OPERATION SECTION...................................................715 INTRODUCTION........................................................715 DATA SUMMARY........................................................715 DATA GATHERING......................................................715 COMPONENT DESCRIPTION...............................................716 SYSTEM DIAGRAM..................................................716 SUSPENSION PRESSURE SENSORS.....................................716 INCLINOMETER....................................................716 OPERATOR DISPLAY................................................716 OPERATOR SWITCH.................................................717 SPEED INPUT.....................................................717 BODY - UP SWITCH................................................717 BRAKE LOCK SWITCH...............................................717 PAYLOAD METER...................................................717 COMMUNICATIONS PORT.............................................717 KEYSWITCH INPUT.................................................718 PAYLOAD METER POWER.............................................718 LOAD LIGHTS.....................................................718 WIRING AND TERMINATION..........................................719 TCI OUTPUTS.....................................................719 OPERATOR'S DISPLAY AND SWITCH.......................................720 READING THE SPEEDOMETER.........................................720 READING THE LOAD DISPLAY........................................720 USING THE OPERATOR ID...........................................720 USING THE LOAD AND TON COUNTER..................................720 TOTAL TON COUNTER...........................................720 TOTAL LOAD COUNTER..........................................721 CLEARING THE COUNTERS.......................................721 VIEWING LIVE SENSOR DATA........................................721 OTHER DISPLAY MESSAGES..........................................721 PAYLOAD OPERATION AND CALCULATION...................................722 DESCRIPTION OF HAUL CYCLE STATES................................722 STATES OF HAUL CYLCLE.......................................722 HAUL CYCLE DESCRIPTION......................................722 LOAD CALCULATION................................................723 CARRY BACK......................................................723 MEASUREMENT ACCURACY............................................723 SOURCES FOR PAYLOAD ERROR.......................................723 PAYLOAD ERROR...............................................717 LOADING CONDITIONS..........................................724 PRESSURE SENSORS............................................724 SWINGLOADS..................................................724 SPEED AND DISTANCE..........................................724 HAUL CYCLE DATA.....................................................725 HAUL CYCLE DATA.................................................725 HAUL CYCLE WARNING FLAGS........................................726 ALARM RECORDS...................................................727 FRAME TORQUE DATA...............................................727 SPRUNG WEIGHT DATA..............................................728 MAXIMUM SPEED DATA..............................................728 PC SOFTWARE OVERVIEW................................................728 PC OVERVIEW.....................................................728 SYSTEM CONFIGURATION............................................728 INSTALLING THE PAYLOAD METER III SOFTWARE.......................728 DOWNLOADING DATA....................................................729 PLM III SYSTEM CONFIGURATION........................................730 STARTING COMMUNICATIONS.........................................730 DISPLAYED PAYLOAD UNITS.....................................730 TIME UNITS..................................................730 CONNECTION MENU.................................................730 CONNECTING TO THE PAYLOAD METER.................................731 CONFIGURE THE PAYLOAD METER.....................................731 SETTING THE DATE AND TIME...................................731 SETTING THE TRUCK TYPE......................................732 SETTING THE GAUGE DISPLAY UNITS.............................732 SETTING THE FRAME SERIAL NUMBER.............................732 SETTING THE TRUCK NUMBER....................................732 SETTING THE KMS DISTRIBUTOR.................................732 SETTING THE KMS CUSTOMER....................................732 CLEAN TRUCK TARE................................................733 INCLINOMETER CALIBRATION........................................733 DATA ANALYSIS.......................................................734 CREATING A QUERY................................................734 SORTING ON TRUCK UNIT NUMBER................................734 SORTING ON TRUCK TYPE.......................................728 SORTING ON DATE RANGE.......................................735 SORTING ON TIME RANGE.......................................735 PAYLOAD DETAIL SCREEN...........................................736 CREATING REPORTS................................................736 SUMMARY - ONE PAGE REPORT...................................737 DETAILED - MULTI-PAGE REPORT................................737 CREATING GRAPHS.................................................738 EXPORTING DATA..................................................738 CSV EXPORT..................................................738 COMPRESSED..................................................739 IMPORTING DATA..................................................740 DELETING HAUL CYCLE RECORDS.....................................740 VIEWING ALARMS..................................................741 DELETING ALARM RECORDS..........................................741 TROUBLESHOOTING SECTION.............................................742 TROUBLESHOOTING.................................................742 VIEWING ACTIVE ALARMS...........................................742 REAL-TIME DATA DISPLAY..........................................742 TESTING THE PAYLOAD LIGHTS......................................742 CREATING LOG FILES OF INPUTS....................................743 DAILY INSPECTIONS...............................................743 PERIODIC MAINTENANCE............................................743 ABNORMAL DISPLAYS AT POWER UP...................................744 NO PAYLOAD DISPLAY WHEN KEYSWITCH IS ON.........................745 NO DISPLAY ON SPEEDOMETER.......................................746 NO DISPLAY ON OPERATOR DISPLAY..................................746 NO COMMUNICATIONS WITH PC.......................................747 LOAD LIGHTS DON'T LIGHT DURING LOADING..........................748 LOAD LIGHTS REMAIN ON...........................................749 LOAD LIGHTS REMAIN ON DURING DUMPING............................749 DISPLAY DOESN'T CLEAR WHEN THE LOAD IS DUMPED...................749 CALIBRATION PROBLEMS............................................750 ALARM 1 - LEFT FRONT PRESSURE HIGH..............................751 ALARM 2- LEFT FRONT PRESSURE LOW................................751 TROUBLESHOOT WIRING TO LEFT FRONT SUSPENSION....................751 ALARM 3 - RIGHT FRONT PRESSURE HIGH.............................752 ALARM 4 - RIGHT FRONT PRESSURE LOW..............................752 TROUBLESHOOT WIRING TO RIGHT FRONT SUSPENSION...................752 ALARM 5 - LEFT REAR PRESSURE HIGH...............................753 ALARM 6 - LEFT REAR PRESSURE LOW................................753 TROUBLESHOOT WIRING TO LEFT REAR SUSPENSION.....................753 ALARM 7 - RIGHT REAR PRESSURE HIGH..............................754 ALARM 8 - RIGHT REAR PRESSURE LOW...............................754 TROUBLESHOOT WIRING TO RIGHT REAR SUSPENSION....................754 ALARM 9 - INCLINOMETER HIGH.....................................755 ALARM 10 - INCLINOMETER LOW.....................................755 TROUBLESHOOTING INCLINOMETER WIRING.............................755 ALARM 13 - BODY UP INPUT FAILURE................................756 ALARM 15 - MEMORY WRITE FAILURE.................................757 ALARM 16 - MEMORY READ FAILURE..................................757 ALARM 24 - SYSTEM KEY-ON STATUS.................................757 OPERATOR SWITCH DOESN'T WORK....................................758 ALARM 26 - USER SWITCH FAULT - SELECT...........................758 ALARM 27 - USER SWITCH FAULT - SET..............................758 CONNECTOR MAP...................................................759 CONNECTORS......................................................760 CHECKOUT PROCEDURE SECTION..........................................762 PLM III CHECKOUT PROCEDURE......................................762 GENERAL DESCRIPTION.........................................762 TOOLS REQUIRED..............................................762 CHECKOUT PROCEDURE..........................................762 PLM III CHECKOUT PROCEDURE CONFIRMATION.........................766 1.1 FLASHBURN PROGRAMMING - GENERAL INSTRUCTIONS............766 CONFIRMATION CHECKLIST......................................768 COMPONENTS AND SCHEMATICS SECTION...................................769 PAYLOAD METER III - COMPONENTS..................................769 PRESSURE SENSOR.............................................769 CONTROLLER..................................................769 SPEEDOMETER.................................................769 N. OPERATOR'S CAB...........................................................770 TRUCK CAB...............................................................772 DESCRIPTION.........................................................772 REMOVAL.........................................................773 INSTALLATION....................................................774 CAB DOOR............................................................775 REMOVAL.........................................................775 INSTALLATION....................................................775 DOOR ADJUSTMENT.................................................775 DOOR GLASS REPLACEMENT..........................................778 DOOR HANDLE OR LATCH REPLACEMENT................................782 DOOR AND DOOR HINGE SEAL REPLACEMENT............................783 GLASS REPLACEMENT...................................................784 ADHESIVE BONDED WINDOWS.........................................784 WINDSHIELD AND REAR GLASS REPLACEMENT...........................785 CAB COMPONENTS..........................................................788 WINDSHIELD WIPER....................................................788 WINDSHIELD WASHER...................................................790 OPERATOR COMFORT........................................................792 OPERATOR SEAT.......................................................792 ADJUSTMENT......................................................792 REMOVAL.........................................................792 INSTALLATION....................................................792 HEATER / AIR CONDITIONER................................................793 OPERATION...........................................................793 HEATER COMPONENTS.......................................................794 CIRCUIT BREAKERS....................................................794 HEATER CORE.........................................................795 FAN MOTOR AND SPEED CONTROL.........................................795 ACTUATORS...........................................................795 FILTER..............................................................795 OPERATOR CONTROLS.......................................................798 STEERING COLUMN.....................................................799 REMOVAL.........................................................799 INSTALLATION....................................................800 PEDAL CONTROLS......................................................801 THROTTLE PEDAL..................................................801 SERVICE BRAKE PEDAL.............................................801 DUAL FUNCTION / SINGLE BRAKE PEDAL..............................801 DYNAMIC RETARDING PEDAL.........................................801 CONSOLE CONTROLS........................................................803 INSTRUMENT PANEL........................................................807 OVERHEAD CONTROLS, GAUGES...............................................813 INDICATOR LIGHTS........................................................814 CENTRY FUEL SYSTEM......................................................821 DETERMINING FAULT CODES.............................................821 P. LUBRICATION AND SERVICE..................................................830 LUBRICATION AND SERVICE.................................................832 SERVICE CAPACITIES..................................................832 HYDRAULIC TANK SERVICE..............................................832 HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS).......................832 COOLANT LEVEL CHECK.................................................833 RADIATOR FILLING PROCEDURE..........................................833 COOLING SYSTEM RECOMMENDATIONS......................................833 LUBRICATION CHART...................................................834 10 HOURS........................................................835 50 HOURS........................................................837 100 HOURS.......................................................838 250 HOURS.......................................................839 500 HOURS.......................................................841 1000 HOURS......................................................842 5000 HOURS......................................................843 LINCOLN AUTOMATIC LUBRICATION SYSTEM....................................844 GENERAL DESCRIPTION.................................................844 SYSTEM COMPONENTS...................................................846 SYSTEM OPERATION....................................................829 GENERAL INSTRUCTIONS................................................850 SYSTEM PRIMING..................................................850 LUBRICANT PUMP..................................................850 FILTER AND RESERVOIR............................................851 INJECTORS.......................................................852 SYSTEM CHECK-OUT....................................................853 24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT...................853 PUMP REBUILD........................................................854 DISASSEMBLY.....................................................854 CLEANING AND INSPECTION.........................................854 ASSEMBLY........................................................856 PREVENTATIVE MAINTENANCE PROCEDURE..................................860 MOTORIZED WHEEL MAINTENANCE SCHEDULE....................................862 Q. ALPHABETICAL INDEX.......................................................866 R. SYSTEM SCHEMATICS........................................................870 HYDRAULIC BRAKE SYSTEM SCHEMATIC........................................872 HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE)................................873 ELECTRICAL SCHEMATIC....................................................874 PAYLOAD METER III ELECTRICAL SCHEMATIC..................................902
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