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Komatsu 730E Dump Truck Service Manual SN A30181-A30211 – PDF DOWNLOAD
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Komatsu 730E Dump Truck Service Manual
Book Code: CEBM006701
SERIAL NUMBER A30181 – A30211
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Description
Komatsu 730E Dump Truck Service Manual
FILE DETAILS:
Komatsu 730E Dump Truck Service Manual
Language : English
Pages : 850
Downloadable : Yes
File Type : PDF
Size: 22.2 MB
Book Code: CEBM006701
KOMATSU 730E DUMP TRUCK SERVICE MANUAL SN A30181-A30211 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 730E Dump Truck Service 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, wamings 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 infomtation. 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 nomtal seated position, unless specifically stated otherwise- Standard torque requirements are shown in torque charts in the general infomiation section and individual torques are provided in the text in bold face type, such as 100 ft.Ibs. (135 N.m) torque- All torque specifications have i 10% tolerance unless otherwise specified.
- A Product Identification plate is nomtally 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.”/.W. (Gross Vehicle Weight) rating.
- The KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (Le. 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 ldentifi cation Number (vehicle serial number) contains infomiation 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 Service 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................................................... 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........................................124 OPERATION.......................................................124 TROUBLESHOOTING.................................................126 24 VDC ELECTRICAL SYSTEM COMPONENTS.....................................128 PASSENGER SEAT BASE COMPARTMENT.....................................128 TAIL LIGHT RESISTOR DIODE ASSEMBLIES............................128 5 MINUTE IDLE TIMER COMPONENTS..................................128 ALARM INDICATING DEVICE (A.I.D. SYSTEM..........................130 BODY UP SWITCH......................................................132 HOIST LIMIT SWITCH..................................................133 GROUND LEVEL SHUTDOWN...............................................134 24 VDC RELAY AND DIODE BOARDS.......................................135 DESCRIPTION.....................................................136 RELAY BOARD 1 (TURN SIGNAL).....................................138 RELAY BOARD 2 (PAYLOAD METER)...................................138 RELAY BOARD 3 (STOP LIGHTS).....................................138 RELAY BOARD 4 (PARKING BRAKE)...................................138 RELAY BOARD 5 (HEADLIGHTS)......................................139 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......................................175 PROGRAMMING THE TRUCK...........................................186 PTU HOOKUP..................................................186 DOWNLOAD CONFIGURATION FILES................................188 EVENT DATA......................................................190 STATISTICAL DATA................................................192 STATISTICAL DATA CODES - COUNTERS (TABLE III)...............193 STATISTICAL DATA CODES - PROFILES (TABLE IV)................199 TRUCK SPECIFIC INFORMATION......................................203 TEMPORARY TRUCK SETTINGS........................................204 MISCELLANEOUS SOFTWARE FEATURES.................................205 SAVING DATA.................................................205 PTU ABBREVIATIONS...........................................206 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..........................208 ALTERNATOR..........................................................208 ELECTRIC WHEEL MOTORS...............................................208 RETARDING GRIDS.....................................................208 ELECTRONIC ACCELERATOR AND RETARD CONTROL...........................208 COOLING BLOWER WARNING SYSTEM.......................................210 ELECTRICAL CONTROL CABINET..........................................211 STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS.................. 0 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.........................................................276 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)................................301 ASSEMBLY (COMPLETE).............................................302 SUSPENSION PRESSURE TEST............................................303 REAR SUSPENSION.........................................................304 REMOVAL.............................................................304 INSTALLATION........................................................306 DISASSEMBLY.....................................................307 ASSEMBLY........................................................307 SUSPENSION PRESSURE TEST............................................309 OILING AND CHARGING PROCEDURES.......................................... 0 GENERAL............................................................. 0 EQUIPMENT LIST...................................................... 0 FRONT SUSPENSION.................................................... 0 FRONT SUSPENSION OILING......................................... 0 FRONT SUSPENSION NITROGEN CHARGING.............................. 0 REAR SUSPENSION..................................................... 0 REAR SUSPENSION OILING.......................................... 0 REAR SUSPENSION NITROGEN CHARGING............................... 0 OIL AND NITROGEN SPECIFICATIONS......................................... 0 J. BRAKE CIRCUIT............................................................318 BRAKE CIRCUIT...........................................................320 SERVICE BRAKE CIRCUIT OPERATION.....................................320 SECONDARY BRAKING AND AUTOMATIC APPLY...............................322 PARKING BRAKE CIRCUIT...............................................322 BRAKE LOCK CIRCUIT..................................................323 WARNING CIRCUIT.....................................................323 BRAKE VALVE CUT-AWAY................................................324 BRAKE CIRCUIT COMPONENT SERVICE.........................................326 BRAKE VALVE.........................................................326 REMOVAL.........................................................326 INSTALLATION....................................................328 DISASSEMBLY.....................................................329 CLEANING AND INSPECTION.........................................331 ASSEMBLY........................................................331 BENCH TEST AND ADJUSTMENT.......................................335 INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE....338 INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE.......339 HYDRAULIC BRAKE ACCUMULATORS........................................340 REMOVAL.........................................................340 INSTALLATION....................................................340 DISASSEMBLY.....................................................340 CLEANING AND INSPECTION.........................................341 ASSEMBLY........................................................342 CHARGING PROCEDURE..............................................343 BRAKE CIRCUIT CHECKOUT PROCEDURE........................................344 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...........................350 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET...................354 FRONT BRAKES (ROCKWELL).................................................356 BRAKE CALIPER.......................................................356 BRAKE LINING........................................................360 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE.......................361 TEMPORARY BRAKE DISCONNECT (DISABLE) PROCEDURE......................361 BRAKE BLEEDING PROCEDURE............................................363 REAR BRAKES (ROCKWELL)..................................................364 BRAKE CALIPER, DISC AND PARKING BRAKE...............................364 CALIPER PISTON ASSEMBLY.............................................369 BENCH TEST..........................................................375 BRAKE LINING........................................................376 BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE........................378 BRAKE BLEEDING PROCEDURE............................................379 PARKING BRAKE (ROCKWELL)................................................382 CALIPER STYLE IDENTIFICATION (SCL15 VS. SCL70)......................382 REMOVAL.........................................................383 INSTALLATION....................................................383 PARKING BRAKE ADJUSTMENT (SCL 70)...............................383 PARKING BRAKE ADJUSTMENT (SCL 15).......................................385 PARK BRAKE CALIPER DISASSEMBLY......................................386 CLEANING AN INSPECTION..............................................387 PARK BRAKE CALIPER ASSEMBLY.........................................388 PARK BRAKE LINING.......................................................388 REPLACEMENT.........................................................388 CONDITIONING (BURNISHING PROCEDURE).................................388 BRAKE BLEEDING PROCEDURE................................................388 L. HYDRAULIC SYSTEM.........................................................390 HYDRAULIC SYSTEM........................................................392 HOIST CIRCUIT OPERATION.............................................392 STEERING CIRCUIT OPERATION..........................................394 HYDRAULIC COMPONENT REPAIR..............................................398 HOIST PUMP..........................................................398 REMOVAL.........................................................398 INSTALLATION....................................................399 DISASSEMBLY.....................................................400 INSPECTION......................................................402 ASSEMBLY........................................................403 TROUBLESHOOTING GUIDE...........................................407 HYDRAULIC TANK..........................................................408 FILLING INSTRUCTIONS................................................408 REMOVAL.............................................................409 INSTALLATION........................................................409 STRAINER AND DIFFUSER...............................................409 STEERING CIRCUIT........................................................412 STEERING CIRCUIT OPERATION..........................................412 COMPONENT DESCRIPTION...............................................413 STEERING CONTROL VALVE..........................................413 UNLOADER VALVE..................................................413 BLEED DOWN MANIFOLD VALVE.......................................414 FLOW AMPLIFIER..................................................418 STEERING PUMP...................................................427 ACCUMULATORS....................................................427 STEERING CONTROL VALVE..............................................428 REMOVAL.........................................................428 INSTALLATION....................................................428 REBUILD PROCEDURE...............................................429 DISASSEMBLY.................................................429 CLEANING AND INSPECTION.....................................430 ASSEMBLY....................................................432 STEERING PUMP...................................................435 REMOVAL.....................................................435 INSTALLATION................................................435 DISASSEMBLY.................................................437 INSPECTION..................................................437 ASSEMBLY....................................................437 STEERING CIRCUIT COMPONENT REPAIR...................................440 BLEEDDOWN MANIFOLD VALVE........................................440 STEERING ACCUMULATORS...........................................441 STEERING ACCUMULATORS CHARGING PROCEDURE........................445 FLOW AMPLIFIER..................................................446 STEERING CYLINDERS..............................................450 HOIST CIRCUIT.......................................................452 HOIST CIRCUIT OPERATION.........................................452 COMPONENT DESCRIPTION...........................................453 HOIST CIRCUIT COMPONENT REPAIR......................................466 HOIST VALVE.....................................................466 HOIST PILOT VALVE...............................................474 HOIST-UP LIMIT SOLENOID VALVE...................................477 HOIST CYLINDERS.................................................477 HYDRAULIC SYSTEM FILTERS............................................486 HOIST CIRCUIT FILTER............................................486 STEERING CIRCUIT FILTER.........................................488 HYDRAULIC CHECKOUT PROCEDURES.......................................492 STEERING CIRCUIT TEST PROCEDURE.................................492 PRESSURE CHECK AND ADJUSTMENT PROCEDURE.....................492 COMPONENT LEAKAGE TEST......................................494 TROUBLESHOOTING CHART...........................................496 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURES....................499 POWER UP RELIEF PRESSURE TEST...............................499 POWER DOWN RELIEF PRESSURE TEST.............................500 HOIST COUNTERBALANCE VALVE ADJUSTMENT.......................501 DISABLED TRUCK DUMPING PROCEDURE................................502 HYDRAULIC SYSTEM FLUSHING PROCEDURE.............................503 M. OPTIONS AND SPECIAL TOOLS................................................506 FIRE CONTROL SYSTEMS....................................................508 ANSUL FIRE CONTROL PNEUMATIC SYSTEM.................................508 ANSUL FIRE CONTROL ELECTRIC SYSTEM..................................514 ANSUL FIRE CONTROL SYSTEM MANUAL....................................508 OPERATION.......................................................508 INSPECTION AND MAINTENANCE......................................508 RECHARGING PROCEDURES...........................................509 ALTERNATOR AND WHEEL MOTOR COOLING AIR FILTER SYSTEM....................526 SYSTEM ADJUSTMENT...................................................526 PUMP................................................................526 BLOWER DRIVE MOTOR..................................................529 BLOWER BEARING REPAIR...............................................532 AIR CLEANER.........................................................533 WIGGINS QUICK FILL FUEL SYSTEM..........................................534 TANK BREATHER VALVE.................................................535 FUEL RECEIVER.......................................................536 FAN DRIVE CLUTCH - HYDRAULIC ACTUATED...................................538 GENERAL DESCRIPTION.................................................538 MAINTENANCE.........................................................541 TROUBLESHOOTING.....................................................543 FIELD CHECK DIAGNOSIS...............................................544 THERMAL SENSOR AND SOLENOID VALVE...............................545 TROUBLESHOOTING CHART...............................................548 DISASSEMBLY.........................................................552 REASSEMBLY..........................................................559 INSPECTION OF PARTS.................................................570 REBUILD TOOLS.......................................................574 ENGINE COOLANT HEATER SYSTEM - HOT START - 220 VOLT.....................576 HEATING ELEMENT.....................................................576 THERMOSTAT..........................................................577 ENGINE OIL HEATERS - HOT START - 220 VOLT...............................578 TROUBLESHOOTING.....................................................578 HEATING ELEMENT.....................................................578 ENGINE AND COOLANT HEATERS - 440 VOLT...................................580 TROUBLESHOOTING.....................................................581 COOLANT HEATING ELEMENT.............................................582 OIL HEATING ELEMENT.................................................582 SPECIAL TOOL GROUP......................................................586 HEATER / AIR CONDITIONING SYSTEM........................................594 ENVIRONMENTAL IMPACT................................................594 OPERATOR CAB CONDITIONING...........................................595 PRINCIPLES OF REFRIGERATION.........................................595 MAJOR SYSTEM COMPONENTS.............................................597 SYSTEM SERVICING....................................................601 EVACUATING THE SYSTEM...............................................618 SYSTEM TROUBLESHOOTING..............................................620 24 VDC ELECTRIC SUPPLY SYSTEM...........................................630 ELECTRICAL SYSTEM DESCRIPTION.......................................630 BATTERY - MAINTENANCE AND SERVICE...................................630 BATTERY CHARGING SYSTEM.............................................632 GENERAL DESCRIPTION.............................................632 TROUBLESHOOTING PROCEDURES......................................632 NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL..............................640 DIMENSIONS..........................................................641 SPECIFICATIONS......................................................642 SERVICE PARTS LIST..................................................643 EXPLODED VIEW.......................................................644 ON VEHICLE TEST.....................................................645 BENCH TEST..........................................................647 STATIC TESTS........................................................648 ALTERNATOR DISASSEMBLY..............................................651 ALTERNATOR ASSEMBLY.................................................656 SERVICE TOOL INSTRUCTIONS...........................................665 FUEL - WATER SEPARATOR..................................................668 INSTALLATION........................................................668 OPERATION...........................................................668 FILTER SERVICE......................................................669 PAYLOAD METER II - OBWS.................................................670 GENERAL INFORMATION.................................................673 HAUL CYCLES.....................................................673 LIGHTS, SWITCHES, AND COMPONENTS....................................674 TIPS FOR OPERATION..................................................675 EXTERNAL DISPLAY LIGHTS.............................................675 THEORY OF OPERATION.................................................676 BASIC DESCRIPTION...............................................676 INCLINOMETER....................................................676 LINKAGE FACTOR..................................................676 GAIN FACTOR.....................................................677 BRAKE FACTOR....................................................677 SOURCES OF ERROR................................................677 TYPICAL DATA FROM SERVICE CHECK MODE............................677 EXAMPLE CALCULATION OF PAYLOAD..................................678 VIEWING PAYLOAD CALCULATION INPUTS..............................678 CHECKING THE GAIN...............................................679 ADJUSTING THE GAIN..............................................679 TYPES OF DATA STORED................................................680 CYCLE DATA......................................................680 ENGINE ON / OFF DATA............................................681 FAULT CODES AND WARNING DATA....................................681 ENGINE OPERATION................................................682 TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES........................682 OTHER DATA......................................................682 OPERATOR FUNCTIONS..................................................683 USING THE OPERATOR CHECK MODE...................................683 VIEWING THE OPERATOR LOAD COUNTER...............................683 CLEARING THE OPERATOR LOAD COUNTER..............................683 DIMMING THE LIGHTS ON THE DISPLAY...............................683 INITIAL SETUP OF PAYLOAD METER......................................684 SWITCH SETTINGS.................................................684 CHECKING THE OPERATOR CHECK MODE................................685 CHECKING THE SERVICE CHECK MODE.................................685 SETTING "UP:XX".............................................685 SETTING "PL:00".............................................685 CHECKING THE Gt SETTING.........................................686 CHECKING THE INCLINOMETER SETTING...............................686 CALIBRATING A TRUCK.............................................686 DISPLAYS AT START-UP................................................687 SET-UP AND MAINTENANCE..............................................688 SETTING THE SPEED LIMIT.........................................688 SETTING THE OPTION CODE.........................................688 SETTING THE MACHINE ID..........................................689 SETTING THE OPERATOR ID.........................................689 SETTING THE TIME AND DATE.......................................689 DOWNLOAD OF INFORMATION.............................................690 DISPLAY OF FAULT CODES..............................................690 CHARTS OF FAULT CODES AND OTHER INFORMATION.........................692 MONITORING INPUT SIGNALS............................................694 SERVICE CHECK MODE..................................................694 UP FACTOR - PAYLOAD CALCULATION GAIN................................695 PL MODE - LOAD CALCULATION TIMING...................................695 FINAL GEAR RATIO SELECTION..........................................696 BATTERY REPLACEMENT PROCEDURE.......................................697 REPLACING THE BATTERY...........................................697 AFTER REPLACING THE BATTERY.....................................698 SUSPENSION PRESSURE SENSOR..........................................698 REMOVAL.........................................................698 INSTALLATION....................................................699 INCLINOMETER........................................................699 REMOVAL.........................................................699 INSTALLATION....................................................699 ADJUSTMENT......................................................699 PAYLOAD METER BACK PANEL............................................700 CONNECTIONS (AMP PIN ID)............................................701 PAYLOAD METER 2 REINITIALIZATION PROCEDURE..........................702 PAYLOAD CIRCUIT NUMBERS.............................................703 TROUBLESHOOTING SECTION.............................................704 COMMON PROBLEMS.....................................................704 SUSPENSION CHARGING.............................................704 SYMPTOM TABLE...................................................705 MISSING BODY-UP SIGNAL..........................................705 MISSING SPEED SIGNAL............................................706 F-18: R-TERMINAL, OIL PRESSURE SIGNALS..........................706 SHORTED 18V SENSOR POWER SUPPLY (930E)..........................706 FAULT TREE DIAGNOSIS................................................707 PAYLOAD LIGHTS WON'T ILLUMINATE.................................707 RED, AMBER, OR GREEN PAYLOAD LIGHTS DON'T ILLUMINATE............708 CANNOT DOWNLOAD - PC COMMUNICATIONS.............................709 PC COMMUNICATIONS CONFIGURATION.................................710 F.CAL: PAYLOAD METER WON'T CALIBRATE............................711 F-20: SENSOR POWER FAULT........................................712 F-21 THRU F-28 PRESSURE SENSOR FAULTS...........................714 F-31, F-32: INCLINOMETER........................................716 BODY UP INPUT...................................................718 BRAKE LOCK INPUT................................................719 SPEED SIGNAL....................................................720 CONNECTORS AND PRESSURE SENSORS.....................................722 REAL-TIME PAYLOAD METER 2 MONITOR PROGRAM...........................725 DATA DEFINITIONS AND COMMENTS...................................726 TRUCK STATUS AND INPUTS.........................................727 MENU FUNCTIONS..................................................728 USING SCOPE.....................................................728 LOG FILE INFORMATION............................................728 CONNECTIONS TO PAYLOAD METER 2..................................729 USING SCOPE.........................................................730 MONITORING INPUTS USING SCOPE...................................730 MONITORING SUSPENSION CHARGING USING SCOPE......................730 PRESSURE SENSOR DUMMY LOADS.....................................733 GAIN ADJUSTMENT WORKSHEET...........................................734 N. OPERATOR'S CAB...........................................................736 TRUCK CAB...............................................................738 DESCRIPTION.........................................................738 REMOVAL.........................................................739 INSTALLATION....................................................740 CAB DOOR............................................................741 REMOVAL.........................................................741 INSTALLATION....................................................741 DOOR ADJUSTMENT.................................................741 DOOR GLASS REPLACEMENT..........................................744 DOOR HANDLE OR LATCH REPLACEMENT................................748 DOOR AND DOOR HINGE SEAL REPLACEMENT............................749 GLASS REPLACEMENT...................................................750 ADHESIVE BONDED WINDOWS.........................................750 WINDSHIELD AND REAR GLASS REPLACEMENT...........................751 CAB COMPONENTS..........................................................752 WINDSHIELD WIPER....................................................752 WINDSHIELD WASHER...................................................753 OPERATOR COMFORT........................................................754 OPERATOR SEAT.......................................................754 ADJUSTMENT......................................................754 REMOVAL.........................................................754 INSTALLATION....................................................754 HEATER / AIR CONDITIONER................................................755 OPERATION...........................................................755 HEATER COMPONENTS.......................................................756 CIRCUIT BREAKERS....................................................757 HEATER CONTROL COMPONENTS...........................................757 HEATER COIL.........................................................757 FAN MOTOR AND SPEED CONTROL.........................................758 ACTUATORS...........................................................758 FILTER..............................................................758 OPERATOR CONTROLS.......................................................760 STEERING COLUMN.....................................................760 REMOVAL.........................................................760 INSTALLATION....................................................760 PEDAL CONTROLS......................................................762 SERVICE BRAKE PEDAL.............................................762 DUAL FUNCTION / SINGLE BRAKE PEDAL..............................762 DYNAMIC RETARDING PEDAL.........................................762 THROTTLE PEDAL..................................................762 CONSOLE CONTROLS........................................................763 OVERHEAD CONTROLS, GAUGES...............................................765 INSTRUMENT PANEL........................................................766 INDICATOR LIGHTS........................................................770 CENTRY FUEL SYSTEM......................................................776 DIAGNOSTICS.........................................................776 DETERMINING FAULT CODES.............................................777 P. LUBRICATION AND SERVICE..................................................778 LUBRICATION AND SERVICE.................................................780 SERVICE CAPACITIES..................................................780 HYDRAULIC TANK SERVICE..............................................780 HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS).......................780 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....................................................823
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