Komatsu 730E Dump Truck Shop Manual CEBM014800 – PDF DOWNLOAD
FILE DETAILS:
Komatsu 730E Dump Truck Shop Manual CEBM014800 – PDF DOWNLOAD
Language : English
Pages : 868
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 730E Dump Truck Shop Manual CEBM014800 – PDF DOWNLOAD
SERIAL NUMBERS A30310, A30312 AND UP
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 “M” designates a Mechanical drive and the letter “E” designates an
Electrical propulsion system. - The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
(GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
Komatsu 730E Dump Truck Shop Manual CEBM014800 – PDF DOWNLOAD
SERIAL NUMBERS A30310, A30312 AND UP
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 40
CHARTS AND TABLES 48
STORAGE PROCEDURES 54
B STRUCTURES 72
STRUCTURAL COMPONENTS 74
GRILLE AND HOOD 74
LADDERS 75
DECKS 75
RIGHT DECK AND COMPONENTS 75
LEFT DECK 75
DUMP BODY 78
INSTALLATION 78
REMOVAL 78
BODY PADS 79
BODY GUIDE 80
BODY SLING 80
BODY POSITION INDICATOR 80
ROCK EJECTORS 81
HOIST LIMIT SWITCHES 81
FUEL TANK 82
REMOVAL 82
INSTALLATION 83
CLEANING 83
VENT 83
FUEL GAUGE SENDER 83
C ENGINE, FUEL, COOLING, AND AIR CLEANER 84
POWER MODULE 86
REMOVAL 86
INSTALLATION 90
COOLING SYSTEM 0
RADIATOR 0
REMOVAL 0
SERVICE 0
INSTALLATION 0
RADIATOR FILL PROCEDURE 0
COOLING SYSTEM TROUBLESHOOTING 0
POWER TRAIN 100
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 100
REMOVAL 100
ENGINE / ALTERNATOR MATING 102
ALTERNATOR MEASUREMENT 102
ENGINE END PLAY MEASUREMENT 103
DETERMINING SHIM REQUIREMENTS 103
INSTALLATION 104
ENGINE 106
REMOVAL 106
INSTALLATION 106
AIR CLEANERS 108
FILTER ELEMENT REPLACEMENT 108
MAIN FILTER ELEMENT CLEANING 110
PRECLEANER SECTION 111
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 136
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) 160
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 197
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 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 0
INSTALLATION 286
DISASSEMBLY 286
CLEANING AND INSPECTION 287
ASSEMBLY 287
WHEEL BEARING ADJUSTMENT (TIRE REMOVED) 289
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 0
ASSEMBLY 0
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 325
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 346
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 354
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 384
BRAKE LINING 390
BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE 393
BRAKE BLEEDING PROCEDURE 395
PARKING BRAKE (ROCKWELL) 396
CALIPER 396
REMOVAL 396
INSTALLATION 397
PARKING BRAKE ADJUSTMENT (SCL 70) 397
PARKING BRAKE ADJUSTMENT 397
PARK BRAKE CALIPER DISASSEMBLY 399
CLEANING AN INSPECTION 399
PARK BRAKE CALIPER ASSEMBLY 400
PARK BRAKE LINING 401
REPLACEMENT 401
CONDITIONING (BURNISHING PROCEDURE) 401
BRAKE BLEEDING PROCEDURE 401
L HYDRAULIC SYSTEM 402
HYDRAULIC SYSTEM 404
HOIST CIRCUIT OPERATION 404
STEERING CIRCUIT OPERATION 406
HYDRAULIC COMPONENT REPAIR 410
HOIST PUMP 410
REMOVAL 410
INSTALLATION 411
DISASSEMBLY 412
INSPECTION 414
ASSEMBLY 415
TROUBLESHOOTING GUIDE 419
HYDRAULIC TANK 420
FILLING INSTRUCTIONS 420
REMOVAL 421
INSTALLATION 421
STRAINER AND DIFFUSER 421
STEERING CIRCUIT 424
STEERING CIRCUIT OPERATION 424
COMPONENT DESCRIPTION 425
STEERING CONTROL VALVE 425
UNLOADER VALVE 425
BLEED DOWN MANIFOLD VALVE 426
FLOW AMPLIFIER 430
STEERING PUMP 439
ACCUMULATORS 439
STEERING CONTROL VALVE 440
REMOVAL 440
INSTALLATION 440
REBUILD PROCEDURE 441
DISASSEMBLY 441
CLEANING AND INSPECTION 442
ASSEMBLY 444
STEERING PUMP 447
REMOVAL 447
INSTALLATION 447
DISASSEMBLY 449
INSPECTION 449
ASSEMBLY 449
STEERING CIRCUIT COMPONENT REPAIR 452
BLEEDDOWN MANIFOLD VALVE 452
STEERING ACCUMULATORS 453
STEERING ACCUMULATORS CHARGING PROCEDURE 458
FLOW AMPLIFIER 462
STEERING CYLINDERS 467
HOIST CIRCUIT 474
HOIST CIRCUIT OPERATION 474
COMPONENT DESCRIPTION 475
HOIST CIRCUIT COMPONENT REPAIR 488
HOIST VALVE 488
HOIST PILOT VALVE 496
HOIST-UP LIMIT SOLENOID VALVE 499
HOIST CYLINDERS 499
HYDRAULIC SYSTEM FILTERS 508
HOIST CIRCUIT FILTER 508
STEERING CIRCUIT FILTER 510
HYDRAULIC CHECKOUT PROCEDURES 514
INITIAL START UP AND FLUSHING 515
ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE 518
COMPONENT CHECKOUT AND ADJUSTMENT 516
MANIFOLD REASSEMBLY 519
OIL CLEANLINESS CHECK 520
COUNTERBALANCE VALVE ADJUSTMENT 519
DISABLED TRUCK DUMPING PROCEDURE 521
TROUBLESHOOTING CHARTS 522
M OPTIONS AND SPECIAL TOOLS 530
FIRE CONTROL SYSTEMS 532
ANSUL FIRE CONTROL PNEUMATIC SYSTEM 532
ANSUL FIRE CONTROL ELECTRIC SYSTEM 538
ANSUL FIRE CONTROL SYSTEM MANUAL 548
OPERATION 548
INSPECTION AND MAINTENANCE 548
RECHARGING PROCEDURES 549
WIGGINS QUICK FILL FUEL SYSTEM 550
TANK BREATHER VALVE 551
FUEL RECEIVER 550
FAN DRIVE CLUTCH – HYDRAULIC ACTUATED 554
GENERAL DESCRIPTION 554
MAINTENANCE 557
TROUBLESHOOTING 559
FIELD CHECK DIAGNOSIS 560
THERMAL SENSOR AND SOLENOID VALVE 561
TROUBLESHOOTING CHART 564
DISASSEMBLY 568
REASSEMBLY 575
INSPECTION OF PARTS 586
REBUILD TOOLS 591
ENGINE COOLANT HEATER SYSTEM – HOT START – 220 VOLT 592
HEATING ELEMENT 592
THERMOSTAT 593
ENGINE OIL HEATERS – HOT START – 220 VOLT 594
TROUBLESHOOTING 0
HEATING ELEMENT 594
ENGINE AND COOLANT HEATERS – 440 VOLT 596
TROUBLESHOOTING 597
COOLANT HEATING ELEMENT 598
OIL HEATING ELEMENT 599
SPECIAL TOOL GROUP 602
HEATER / AIR CONDITIONING SYSTEM 610
ENVIRONMENTAL IMPACT 610
OPERATOR CAB CONDITIONING 611
PRINCIPLES OF REFRIGERATION 611
MAJOR SYSTEM COMPONENTS 613
SYSTEM SERVICING 617
EVACUATING THE SYSTEM 634
SYSTEM TROUBLESHOOTING 636
24 VDC ELECTRIC SUPPLY SYSTEM 646
ELECTRICAL SYSTEM DESCRIPTION 646
BATTERY – MAINTENANCE AND SERVICE 646
BATTERY CHARGING SYSTEM 648
GENERAL DESCRIPTION 648
TROUBLESHOOTING PROCEDURES 648
NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL 656
DIMENSIONS 657
SPECIFICATIONS 658
SERVICE PARTS LIST 659
EXPLODED VIEW 660
ON VEHICLE TEST 661
BENCH TEST 663
STATIC TESTS 664
ALTERNATOR DISASSEMBLY 667
ALTERNATOR ASSEMBLY 672
SERVICE TOOL INSTRUCTIONS 681
FUEL – WATER SEPARATOR 684
INSTALLATION 684
OPERATION 684
FILTER SERVICE 685
PAYLOAD METER III 686
OPERATION SECTION 689
INTRODUCTION 689
DATA SUMMARY 689
DATA GATHERING 689
COMPONENT DESCRIPTION 690
SYSTEM DIAGRAM 690
SUSPENSION PRESSURE SENSORS 690
INCLINOMETER 690
OPERATOR DISPLAY 690
OPERATOR SWITCH 691
SPEED INPUT 691
BODY-UP SWITCH 691
BRAKE LOCK SWITCH 691
PAYLOAD METER 691
COMMUNICATIONS PORT 691
KEYSWITCH INPUT 692
PAYLOAD METER POWER 692
LOAD LIGHTS 692
WIRING AND TERMINATION 693
TCI OUTPUTS 693
OPERATOR’S DISPLAY AND SWITCH 694
READING THE SPEEDOMETER 694
READING THE LOAD DISPLAY 694
USING THE OPERATOR ID 694
USING THE LOAD AND TON COUNTER 694
TOTAL TON COUNTER 686
TOTAL LOAD COUNTER 695
CLEARING THE COUNTERS 695
VIEWING LIVE SENSOR DATA 695
OTHER DISPLAY MESSAGES 695
PAYLOAD OPERATION AND CALCULATION 696
DESCRIPTION OF HAUL CYCLE STATES 696
STAGES OF A TYPICAL HAUL CYCLE 696
HAUL CYCLE DESCRIPTION 696
LOAD CALCULATION 697
CARRY BACK 697
MEASUREMENT ACCURACY 697
SOURCES FOR PAYLOAD ERROR 697
PAYLOAD ERROR 697
LOADING CONDITIONS 698
PRESSURE SENSORS 698
SWINGLOADS 698
SPEED AND DISTANCE 698
HAUL CYCLE DATA 699
HAUL CYCLE DATA 699
HAUL CYCLE WARNING FLAGS 700
ALARM RECORDS 701
FRAME TORQUE DATA 701
SPRUNG WEIGHT DATA 702
MAXIMUM SPEED DATA 702
PC SOFTWARE OVERVIEW 702
PC OVERVIEW 702
SYSTEM CONFIGURATION 702
INSTALLING THE PAYLOAD METER III SOFTWARE 702
DOWNLOADING DATA 703
PLM III SYSTEM CONFIGURATION 704
STARTING COMMUNICATIONS 704
DISPLAYED PAYLOAD UNITS 704
TIME UNITS 704
CONNECTION MENU 704
CONNECTING TO THE PAYLOAD METER 705
CONFIGURE THE PAYLOAD METER 705
SETTING THE DATE AND TIME 705
SETTING THE TRUCK TYPE 706
SETTING THE GAUGE DISPLAY UNITS 706
SETTING THE FRAME SERIAL NUMBER 706
SETTING THE TRUCK NUMBER 706
SETTING THE KOMATSU DISTRIBUTOR 706
SETTING THE KOMATSU CUSTOMER 706
CLEAN TRUCK TARE 707
INCLINOMETER CALIBRATION 707
DATA ANALYSIS 708
CREATING A QUERY 708
SORTING ON TRUCK UNIT NUMBER 708
SORTING ON TRUCK TYPE 708
SORTING ON DATE RANGE 709
SORTING ON TIME RANGE 709
PAYLOAD DETAIL SCREEN 710
CREATING REPORTS 710
SUMMARY – ONE PAGE REPORT 711
DETAILED – MULTI PAGE REPORT 711
CREATING GRAPHS 712
EXPORTING DATA 712
CSV EXPORT 712
COMPRESSED 713
IMPORTING DATA 714
DELETING HAUL CYCLE RECORDS 714
VIEWING ALARMS 715
DELETING HAUL CYCLE RECORDS 715
VIEWING ALARMS 715
DELETING ALARM RECORDS 715
TROUBLESHOOTING SECTION 716
TROUBLESHOOTING 716
VIEWING ACTIVE ALARMS 716
REAL-TIME DATA DISPLAY 716
TESTING THE PAYLOAD LIGHTS 716
CREATING LOG FILES OF INPUTS 717
DAILY INSPECTIONS 717
PERIODIC MAINTENANCE 717
ABNORMAL DISPLAYS AT POWER-UP 718
NO PAYLOAD DISPLAY WHEN KEYSWITCH IS TURNED ON 719
NO DISPLAY ON SPEEDOMETER 720
NO DISPLAY ON OPERATOR DISPLAY 720
NO COMMUNICATIONS WITH PC 721
LOAD LIGHTS DON’T LIGHT DURING LOADING 722
LOAD LIGHTS REMAIN ON 723
LOAD LIGHTS REMAIN ON DURING DUMPING 723
DISPLAY DOESN’T CLEAR WHEN THE LOAD IS DUMPED 723
CALIBRATION PROBLEMS 724
ALARM 1 – LEFT FRONT PRESSURE HIGH 725
ALARM 2 – LEFT FRONT PRESSURE LOW 725
TROUBLESHOOT WIRING TO LEFT FRONT SUSPENSION 725
ALARM 3 – RIGHT FRONT PRESSURE HIGH 726
ALARM 4 – RIGHT FRONT PRESSURE LOW 726
TROUBLESHOOT WIRING TO RIGHT FRONT SUSPENSION 726
ALARM 5 – LEFT REAR PRESSURE HIGH 727
ALARM 6 – LEFT REAR PRESSURE LOW 727
TROUBLESHOOT WIRING TO LEFT REAR SUSPENSION 727
ALARM 7 – RIGHT REAR PRESSURE HIGH 728
ALARM 8 – RIGHT REAR PRESSURE LOW 728
TROUBLESHOOT WIRING TO RIGHT REAR SUSPENSION 728
ALARM 9 – INCLINOMETER HIGH 729
ALARM 10 – INCLINOMETER LOW 729
TROUBLESHOOTING INCLINOMETER WIRING 729
ALARM 13 – BODY UP INPUT FAILURE 730
ALARM 15 – MEMORY WRITE FAILURE 731
ALARM 16 – MEMORY READ FAILURE 731
ALARM 24 – SYSTEM KEY-ON STATUS 731
OPERATOR SWITCH DOESN’T WORK 732
ALARM 26 – USER SWITCH FAULT – SELECT 732
ALARM 27 – USER SWITCH FAULT – SET 732
CONNECTOR MAP 733
CONNECTORS 734
CHECKOUT PROCEDURE SECTION 736
PLM III CHECKOUT PROCEDURE 736
GENERAL DESCRIPTION 736
TOOLS REQUIRED 736
CHECKOUT PROCEDURE 736
PLM III CHECKOUT PROCEDURE CONFIRMATION 740
1 1 FLASHBURN PROGRAMMING – GENERAL INSTRUCTIONS 740
CONFIRMATION CHECKLIST 742
COMPONENTS AND SCHEMATICS SECTION 743
PAYLOAD METER III COMPONENTS 743
PRESSURE SENSOR 743
CONTROLLER 743
SPEEDOMETER 743
N OPERATOR’S CAB 744
TRUCK CAB 746
DESCRIPTION 746
REMOVAL 747
INSTALLATION 748
CAB DOOR 749
REMOVAL 749
INSTALLATION 749
DOOR ADJUSTMENT 749
DOOR GLASS REPLACEMENT 752
DOOR HANDLE OR LATCH REPLACEMENT 756
DOOR AND DOOR HINGE SEAL REPLACEMENT 757
GLASS REPLACEMENT 758
ADHESIVE BONDED WINDOWS 758
WINDSHIELD AND REAR GLASS REPLACEMENT 758
CAB COMPONENTS 762
WINDSHIELD WIPER 762
WINDSHIELD WASHER 764
OPERATOR COMFORT 766
OPERATOR SEAT 766
ADJUSTMENT 766
REMOVAL 766
INSTALLATION 766
HEATER / AIR CONDITIONER 767
OPERATION 767
HEATER COMPONENTS 768
CIRCUIT BREAKERS 768
HEATER CONTROL COMPONENTS 768
HEATER CORE 769
FAN MOTOR AND SPEED CONTROL 769
ACTUATORS 769
FILTER 769
OPERATOR CONTROLS 772
STEERING COLUMN 774
REMOVAL 774
INSTALLATION 774
PEDAL CONTROLS 775
THROTTLE PEDAL 775
SERVICE BRAKE PEDAL 775
DUAL FUNCTION / SINGLE BRAKE PEDAL 775
DYNAMIC RETARDING PEDAL 775
CONSOLE CONTROLS 777
INSTRUMENT PANEL 781
INDICATOR LIGHTS 787
CENTRY FUEL SYSTEM 793
DIAGNOSTICS 0
DETERMINING FAULT CODES 0
P LUBRICATION AND SERVICE 796
LUBRICATION AND SERVICE 798
SERVICE CAPACITIES 798
HYDRAULIC TANK SERVICE 798
HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS) 0
COOLANT LEVEL CHECK 799
RADIATOR FILLING PROCEDURE 799
COOLING SYSTEM RECOMMENDATIONS 799
LUBRICATION CHART 800
10 HOURS 801
50 HOURS 803
100 HOURS 803
250 HOURS 804
500 HOURS 806
1000 HOURS 807
5000 HOURS 807
LINCOLN AUTOMATIC LUBRICATION SYSTEM 808
GENERAL DESCRIPTION 808
SYSTEM COMPONENTS 810
SYSTEM OPERATION 811
GENERAL INSTRUCTIONS 814
SYSTEM PRIMING 814
LUBRICANT PUMP 814
FILTER AND RESERVOIR 815
INJECTORS 816
SYSTEM CHECK-OUT 817
24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT 817
PUMP REBUILD 818
DISASSEMBLY 818
CLEANING AND INSPECTION 818
ASSEMBLY 820
PREVENTATIVE MAINTENANCE PROCEDURE 0
MOTORIZED WHEEL MAINTENANCE SCHEDULE 826
Q ALPHABETICAL INDEX 830
R SYSTEM SCHEMATICS 834
HYDRAULIC BRAKE SYSTEM SCHEMATIC 836
HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE) 837
ELECTRICAL SCHEMATIC 838
S.V 14/12/24
