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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30123-A30132) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIA. NUMBER:A30123-A30132
- PUBLICATION NUMBER:CEBM006001
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Description
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30123-A30132) KOMATSU 730E
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30123-A30132) KOMATSU 730E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30123-A30132) KOMATSU 730E
- 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 perfomiing 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 dacriptions, 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 U5. standard and metric (Si) units throughoutand all references to ‘Right‘, “Left”, “Front‘, or “Rear‘ are made with respect to the operator‘s nomial 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 ftlbs. (135 Mm) torque.
- All torque specifications have i 10% tolerance unless otherwise specified. A Product identification plate is nomiaily 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 Haulpak Tmck Model designation consists ofthree numbers and one letter (i.e. 730E).
- The three numbers represent the basic truck model- The letter “M” daignates a Mechanical drive and the letter“En designates an Bectrical propulsion system- The Product identifi cation Number (vehicle serial number) contains infomiation which will identify the original manufacturing bill of material for this unit.
- This complete numberwill be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (Gt/W) is what detemiines the load on the drive train, frame, tires, and other components-The vehicle daign and application guidelines are sensitive to thetotal 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 SERVICE REPAIR MANUAL (SN:A30123-A30132) KOMATSU 730E
COVER........................................................................... 1 FOREWARD........................................................................ 5 CONTENTS........................................................................ 7 A. GENERAL INFORMATION...................................................... 9 TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS............................ 11 GENERAL SAFETY AND TRUCK OPERATION...................................... 15 WARNINGS AND CAUTIONS................................................... 39 CHARTS AND TABLES....................................................... 47 STORAGE PROCEDURES...................................................... 57 B. STRUCTURES............................................................... 77 STRUCTURAL COMPONENTS................................................... 79 GRILLE AND HOOD..................................................... 79 LADDERS............................................................. 80 DECKS............................................................... 80 RIGHT DECK AND COMPONENTS....................................... 80 LEFT DECK....................................................... 80 DUMP BODY............................................................... 83 INSTALLATION........................................................ 83 REMOVAL............................................................. 83 BODY PADS........................................................... 84 BODY GUIDE.......................................................... 85 BODY SLING.......................................................... 85 BODY POSITION INDICATOR............................................. 85 ROCK EJECTORS....................................................... 86 HOIST LIMIT SWITCHES................................................ 86 FUEL TANK............................................................... 87 REMOVAL............................................................. 87 INSTALLATION........................................................ 88 CLEANING............................................................ 88 VENT................................................................ 88 FUEL GAUGE SENDER................................................... 88 C. ENGINE, FUEL, COOLING, AND AIR CLEANER................................... 89 POWER MODULE............................................................ 91 REMOVAL............................................................. 91 INSTALLATION........................................................ 95 COOLING SYSTEM.......................................................... 97 RADIATOR............................................................ 97 REMOVAL......................................................... 97 SERVICE......................................................... 98 INSTALLATION.................................................... 98 RADIATOR FILL PROCEDURE......................................... 99 COOLING SYSTEM TROUBLESHOOTING..................................100 POWER TRAIN.............................................................101 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.......................101 REMOVAL.........................................................101 ENGINE / ALTERNATOR MATING..........................................103 ALTERNATOR MEASUREMENT..........................................103 ENGINE END PLAY MEASUREMENT.....................................104 DETERMINING SHIM REQUIREMENTS...................................104 INSTALLATION....................................................105 ENGINE..............................................................107 REMOVAL.........................................................107 INSTALLATION....................................................107 AIR CLEANERS............................................................109 FILTER ELEMENT REPLACEMENT..........................................109 MAIN FILTER ELEMENT CLEANING........................................111 PRECLEANER SECTION..................................................112 D. ELECTRIC SYSTEM (24 VDC, NON-PROPULSION..................................115 24 VDC ELECTRIC SUPPLY SYSTEM...........................................117 ELECTRICAL SYSTEM DESCRIPTION.......................................117 BATTERY - MAINTENANCE AND SERVICE...................................117 ELECTRIC START SYSTEM...............................................119 OPERATION.......................................................119 REMOVAL.....................................................119 INSTALLATION................................................119 CRANKING MOTOR TROUBLESHOOTING..................................120 DISASSEMBLY.....................................................121 SOLENOID CHECKS.................................................124 ASSEMBLY........................................................125 ENGINE PRELUB STARTER SYSTEM........................................129 OPERATION.......................................................129 TROUBLESHOOTING.................................................131 24 VDC ELECTRICAL SYSTEM COMPONENTS.....................................133 PASSENGER SEAT BASE COMPARTMENT.....................................133 TAIL LIGHT RESISTOR DIODE ASSEMBLIES............................133 5 MINUTE IDLE TIMER COMPONENTS..................................133 ALARM INDICATING DEVICE (A.I.D. SYSTEM..........................135 BODY UP SWITCH......................................................137 HOIST LIMIT SWITCH..................................................138 GROUND LEVEL SHUTDOWN...............................................139 24 VDC RELAY AND DIODE BOARDS.......................................140 DESCRIPTION.....................................................141 RELAY BOARD 1 (TURN SIGNAL).....................................143 RELAY BOARD 2 (PAYLOAD METER)...................................143 RELAY BOARD 3 (STOP LIGHTS).....................................143 RELAY BOARD 4 (PARKING BRAKE)...................................143 RELAY BOARD 5 (HEADLIGHTS)......................................144 RELAY BOARD 6 (AUXILIARY PANEL).................................144 DIODE BOARD 1...................................................145 CIRCUIT BREAKER CHART...........................................146 E. ELECTRIC PROPULSION AND CONTROL..........................................147 ELECTRICAL PROPULSION COMPONENTS........................................149 GENERAL SYSTEM DESCRIPTION..........................................149 CONTROL SYSTEM......................................................149 FL275 PANEL.........................................................151 COMPUTER DESCRIPTION............................................153 SOFTWARE........................................................153 2-DIGIT DISPLAY PANEL...............................................156 EVENTS..........................................................156 FRAMES..........................................................157 WINDOWS.........................................................157 EVENT CODE DESCRIPTIONS (TABLE I)...........................159 SUBCODE DESCRIPTIONS (TABLE II).............................166 PORTABLE TEST UNIT (PTU)............................................169 DESCRIPTION.....................................................169 SOFTWARE INSTALLATION PREPARATION...............................170 THE MAIN MENU...............................................172 PTU SOFTWARE MENU TREE......................................173 CONFIGURATION (CFG) FILE CONVERSION.........................174 STATEX CONFIGURATION FILES......................................180 PROGRAMMING THE TRUCK...........................................191 PTU HOOKUP..................................................191 DOWNLOAD CONFIGURATION FILES................................193 EVENT DATA......................................................195 STATISTICAL DATA................................................197 STATISTICAL DATA CODES - COUNTERS (TABLE III)...............198 STATISTICAL DATA CODES - PROFILES (TABLE IV)................204 TRUCK SPECIFIC INFORMATION......................................208 TEMPORARY TRUCK SETTINGS........................................209 MISCELLANEOUS SOFTWARE FEATURES.................................210 SAVING DATA.................................................210 PTU ABBREVIATIONS...........................................211 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..........................213 ALTERNATOR..........................................................213 ELECTRIC WHEEL MOTORS...............................................213 RETARDING GRIDS.....................................................213 ELECTRONIC ACCELERATOR AND RETARD CONTROL...........................213 COOLING BLOWER WARNING SYSTEM.......................................215 ELECTRICAL CONTROL CABINET..........................................216 ELECTRICAL CHECKOUT PROCEDURE...........................................221 G. DRIVE AXLE, SPINDLES AND WHEELS..........................................273 TIRES AND RIMS (G02012).................................................275 FRONT TIRES AND RIMS................................................276 REMOVAL.........................................................276 INSTALLATION....................................................277 REAR TIRES AND RIMS.................................................277 REMOVAL.........................................................277 INSTALLATION....................................................278 RIM.................................................................279 TIRE REMOVAL....................................................279 TIRE INSTALLATION...............................................280 FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)...........................281 WHEEL HUB AND SPINDLE ASSEMBLY......................................281 REMOVAL.........................................................281 INSTALLATION....................................................283 DISASSEMBLY.....................................................283 CLEANING AND INSPECTION.........................................284 ASSEMBLY........................................................284 WHEEL BEARING ADJUSTMENT (TIRE REMOVED).........................286 WHEEL BEARING ADJUSTMENT (TIRE MOUNTED).........................287 STEERING CYLINDERS AND TIE ROD......................................289 REMOVAL.........................................................289 INSTALLATION....................................................289 BEARING REPLACEMENT.............................................289 TOE-IN ADJUSTMENT...................................................291 REAR AXLE HOUSING ATTACHMENT (G04010)...................................293 PIVOT PIN...........................................................293 REMOVAL.........................................................293 INSTALLATION....................................................293 DISASSEMBLY.....................................................294 ASSEMBLY........................................................294 ANTI-SWAY BAR.......................................................296 REMOVAL.........................................................296 INSTALLATION....................................................296 DISASSEMBLY.....................................................296 CLEANING AND INSPECTION.........................................296 ASSEMBLY........................................................296 REAR AXLE HOUSING (G05004)..............................................297 REAR AXLE HOUSING...................................................297 REMOVAL.........................................................297 INSTALLATION....................................................297 WHEEL MOTOR.........................................................297 REMOVAL.........................................................297 CLEANING AND INSPECTION.........................................298 INSTALLATION....................................................298 H. HYDRAIR II SUSPENSIONS...................................................299 FRONT SUSPENSION........................................................301 REMOVAL.............................................................301 INSTALLATION........................................................302 DISASSEMBLY.....................................................305 ASSEMBLY (BEARING RETAINER ONLY)................................306 ASSEMBLY (COMPLETE).............................................307 SUSPENSION PRESSURE TEST............................................308 REAR SUSPENSION.........................................................309 REMOVAL.............................................................309 INSTALLATION........................................................311 DISASSEMBLY.....................................................312 ASSEMBLY........................................................312 SUSPENSION PRESSURE TEST............................................314 J. BRAKE CIRCUIT............................................................323 BRAKE CIRCUIT...........................................................325 SERVICE BRAKE CIRCUIT OPERATION.....................................325 SECONDARY BRAKING AND AUTOMATIC APPLY...............................327 PARKING BRAKE CIRCUIT...............................................327 BRAKE LOCK CIRCUIT..................................................328 WARNING CIRCUIT.....................................................328 BRAKE VALVE CUT-AWAY................................................329 BRAKE CIRCUIT COMPONENT SERVICE.........................................331 BRAKE VALVE.........................................................331 REMOVAL.........................................................331 INSTALLATION....................................................333 DISASSEMBLY.....................................................334 CLEANING AND INSPECTION.........................................336 ASSEMBLY........................................................336 BENCH TEST AND ADJUSTMENT.......................................340 INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE....343 INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE.......344 HYDRAULIC BRAKE ACCUMULATORS........................................345 REMOVAL.........................................................345 INSTALLATION....................................................345 DISASSEMBLY.....................................................345 CLEANING AND INSPECTION.........................................346 ASSEMBLY........................................................347 CHARGING PROCEDURE..............................................348 BRAKE CIRCUIT CHECKOUT PROCEDURE........................................349 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...........................355 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET...................359 FRONT BRAKES (ROCKWELL).................................................361 BRAKE CALIPER.......................................................361 BRAKE LINING........................................................365 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE.......................366 TEMPORARY BRAKE DISCONNECT (DISABLE) PROCEDURE......................366 BRAKE BLEEDING PROCEDURE............................................368 REAR BRAKES (ROCKWELL)..................................................369 BRAKE CALIPER, DISC AND PARKING BRAKE...............................369 CALIPER PISTON ASSEMBLY.............................................374 BENCH TEST..........................................................380 BRAKE LINING........................................................381 BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE........................383 BRAKE BLEEDING PROCEDURE............................................384 PARKING BRAKE (ROCKWELL)................................................387 CALIPER STYLE IDENTIFICATION (SCL15 VS. SCL70)......................387 REMOVAL.........................................................388 INSTALLATION....................................................388 PARKING BRAKE ADJUSTMENT (SCL 70)...............................388 PARKING BRAKE ADJUSTMENT (SCL 15).......................................390 PARK BRAKE CALIPER DISASSEMBLY......................................391 CLEANING AN INSPECTION..............................................392 PARK BRAKE CALIPER ASSEMBLY.........................................393 PARK BRAKE LINING.......................................................393 REPLACEMENT.........................................................393 CONDITIONING (BURNISHING PROCEDURE).................................393 BRAKE BLEEDING PROCEDURE................................................393 L. HYDRAULIC SYSTEM.........................................................395 HYDRAULIC SYSTEM........................................................397 HOIST CIRCUIT OPERATION.............................................397 STEERING CIRCUIT OPERATION..........................................399 HYDRAULIC COMPONENT REPAIR..............................................403 HOIST PUMP..........................................................403 REMOVAL.........................................................403 INSTALLATION....................................................404 DISASSEMBLY.....................................................405 INSPECTION......................................................407 ASSEMBLY........................................................408 TROUBLESHOOTING GUIDE...........................................412 HYDRAULIC TANK..........................................................413 FILLING INSTRUCTIONS................................................413 REMOVAL.............................................................414 INSTALLATION........................................................414 STRAINER AND DIFFUSER...............................................414 STEERING CIRCUIT........................................................417 STEERING CIRCUIT OPERATION..........................................417 COMPONENT DESCRIPTION...............................................418 STEERING CONTROL VALVE..........................................418 UNLOADER VALVE..................................................418 BLEED DOWN MANIFOLD VALVE.......................................419 FLOW AMPLIFIER..................................................423 STEERING PUMP...................................................432 ACCUMULATORS....................................................432 STEERING CONTROL VALVE..............................................433 REMOVAL.........................................................433 INSTALLATION....................................................433 REBUILD PROCEDURE...............................................434 DISASSEMBLY.................................................434 CLEANING AND INSPECTION.....................................435 ASSEMBLY....................................................437 STEERING PUMP...................................................440 REMOVAL.....................................................440 INSTALLATION................................................440 DISASSEMBLY.................................................442 INSPECTION..................................................442 ASSEMBLY....................................................442 STEERING CIRCUIT COMPONENT REPAIR...................................445 BLEEDDOWN MANIFOLD VALVE........................................445 STEERING ACCUMULATORS...........................................446 STEERING ACCUMULATORS CHARGING PROCEDURE........................450 FLOW AMPLIFIER..................................................451 STEERING CYLINDERS..............................................455 HOIST CIRCUIT.......................................................457 HOIST CIRCUIT OPERATION.........................................457 COMPONENT DESCRIPTION...........................................458 HOIST CIRCUIT COMPONENT REPAIR......................................471 HOIST VALVE.....................................................471 HOIST PILOT VALVE...............................................479 HOIST-UP LIMIT SOLENOID VALVE...................................482 HOIST CYLINDERS.................................................482 HYDRAULIC SYSTEM FILTERS............................................491 HOIST CIRCUIT FILTER............................................491 STEERING CIRCUIT FILTER.........................................493 HYDRAULIC CHECKOUT PROCEDURES.......................................497 STEERING CIRCUIT TEST PROCEDURE.................................497 PRESSURE CHECK AND ADJUSTMENT PROCEDURE.....................497 COMPONENT LEAKAGE TEST......................................499 TROUBLESHOOTING CHART...........................................501 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURES....................504 POWER UP RELIEF PRESSURE TEST...............................504 M. OPTIONS AND SPECIAL TOOLS................................................505 FIRE CONTROL SYSTEMS....................................................507 ANSUL FIRE CONTROL PNEUMATIC SYSTEM.................................507 ANSUL FIRE CONTROL ELECTRIC SYSTEM..................................513 ANSUL FIRE CONTROL SYSTEM MANUAL....................................507 OPERATION.......................................................507 INSPECTION AND MAINTENANCE......................................507 RECHARGING PROCEDURES...........................................508 ALTERNATOR AND WHEEL MOTOR COOLING AIR FILTER SYSTEM....................525 SYSTEM ADJUSTMENT...................................................525 PUMP................................................................525 BLOWER DRIVE MOTOR..................................................528 BLOWER BEARING REPAIR...............................................531 AIR CLEANER.........................................................532 WIGGINS QUICK FILL FUEL SYSTEM..........................................533 TANK BREATHER VALVE.................................................534 FUEL RECEIVER.......................................................535 FAN DRIVE CLUTCH - HYDRAULIC ACTUATED...................................537 GENERAL DESCRIPTION.................................................537 MAINTENANCE.........................................................540 TROUBLESHOOTING.....................................................542 FIELD CHECK DIAGNOSIS...............................................543 THERMAL SENSOR AND SOLENOID VALVE...............................544 TROUBLESHOOTING CHART...............................................547 DISASSEMBLY.........................................................551 REASSEMBLY..........................................................558 INSPECTION OF PARTS.................................................569 REBUILD TOOLS.......................................................573 ENGINE COOLANT HEATER SYSTEM - HOT START - 220 VOLT.....................575 HEATING ELEMENT.....................................................575 THERMOSTAT..........................................................576 ENGINE OIL HEATERS - HOT START - 220 VOLT...............................577 TROUBLESHOOTING.....................................................577 HEATING ELEMENT.....................................................577 ENGINE AND COOLANT HEATERS - 440 VOLT...................................579 TROUBLESHOOTING.....................................................580 COOLANT HEATING ELEMENT.............................................581 OIL HEATING ELEMENT.................................................581 SPECIAL TOOL GROUP......................................................585 HEATER / AIR CONDITIONING SYSTEM........................................591 ENVIRONMENTAL IMPACT................................................591 OPERATOR CAB CONDITIONING...........................................592 PRINCIPLES OF REFRIGERATION.........................................592 MAJOR SYSTEM COMPONENTS.............................................594 SYSTEM SERVICING....................................................598 EVACUATING THE SYSTEM...............................................615 SYSTEM TROUBLESHOOTING..............................................617 24 VDC ELECTRIC SUPPLY SYSTEM...........................................627 ELECTRICAL SYSTEM DESCRIPTION.......................................627 BATTERY - MAINTENANCE AND SERVICE...................................627 BATTERY CHARGING SYSTEM.............................................629 GENERAL DESCRIPTION.............................................629 TROUBLESHOOTING PROCEDURES......................................629 NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL..............................637 DIMENSIONS..........................................................638 SPECIFICATIONS......................................................639 SERVICE PARTS LIST..................................................640 EXPLODED VIEW.......................................................641 ON VEHICLE TEST.....................................................642 BENCH TEST..........................................................644 STATIC TESTS........................................................645 ALTERNATOR DISASSEMBLY..............................................648 ALTERNATOR ASSEMBLY.................................................653 SERVICE TOOL INSTRUCTIONS...........................................662 FUEL - WATER SEPARATOR..................................................665 INSTALLATION........................................................665 OPERATION...........................................................665 FILTER SERVICE......................................................666 PAYLOAD METER II - OBWS.................................................667 TABLE OF CONTENTS...................................................667 GENERAL INFORMATION.............................................670 HAUL CYCLES.................................................670 LIGHTS, SWITCHES, AND COMPONENTS................................671 TIPS FOR OPERATION..............................................672 EXTERNAL DISPLAY LIGHTS.........................................672 THEORY OF OPERATION.............................................673 BASIC DESCRIPTION...........................................673 INCLINOMETER................................................673 LINKAGE FACTOR..............................................673 GAIN FACTOR.................................................674 BRAKE FACTOR................................................674 SOURCES OF ERROR............................................674 TYPICAL DATA FROM SERVICE CHECK MODE........................674 EXAMPLE CALCULATION OF PAYLOAD..............................675 VIEWING PAYLOAD CALCULATION INPUTS..........................675 CHECKING THE GAIN...........................................676 ADJUSTING THE GAIN..........................................676 TYPES OF DATA STORED............................................677 CYCLE DATA..................................................677 ENGINE ON / OFF DATA........................................678 FAULT CODES AND WARNING DATA................................678 ENGINE OPERATION............................................679 TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES....................679 OTHER DATA..................................................679 OPERATOR FUNCTIONS..............................................680 USING THE OPERATOR CHECK MODE...............................680 VIEWING THE OPERATOR LOAD COUNTER...........................680 CLEARING THE OPERATOR LOAD COUNTER..........................680 DIMMING THE LIGHTS ON THE DISPLAY...........................680 INITIAL SETUP OF PAYLOAD METER..................................681 SWITCH SETTINGS.............................................681 CHECKING THE OPERATOR CHECK MODE............................682 CHECKING THE SERVICE CHECK MODE.............................682 SETTING "UP:XX".........................................682 SETTING "PL:00".........................................682 CHECKING THE Gt SETTING.....................................683 CHECKING THE INCLINOMETER SETTING...........................683 CALIBRATING A TRUCK.........................................683 DISPLAYS AT START-UP............................................684 SET-UP AND MAINTENANCE..........................................685 SETTING THE SPEED LIMIT.....................................685 SETTING THE OPTION CODE.....................................685 SETTING THE MACHINE ID......................................686 SETTING THE OPERATOR ID.....................................686 SETTING THE TIME AND DATE...................................686 DOWNLOAD OF INFORMATION.........................................687 DISPLAY OF FAULT CODES..........................................687 CHARTS OF FAULT CODES AND OTHER INFORMATION.....................689 MONITORING INPUT SIGNALS........................................691 SERVICE CHECK MODE..............................................691 UP FACTOR - PAYLOAD CALCULATION GAIN............................692 PL MODE - LOAD CALCULATION TIMING...............................692 FINAL GEAR RATIO SELECTION......................................693 BATTERY REPLACEMENT PROCEDURE...................................694 REPLACING THE BATTERY.......................................694 AFTER REPLACING THE BATTERY.................................695 SUSPENSION PRESSURE SENSOR......................................695 REMOVAL.....................................................695 INSTALLATION................................................696 INCLINOMETER....................................................696 REMOVAL.....................................................696 INSTALLATION................................................696 ADJUSTMENT..................................................696 PAYLOAD METER BACK PANEL........................................697 CONNECTIONS (AMP PIN ID)........................................698 PAYLOAD METER 2 REINITIALIZATION PROCEDURE......................699 PAYLOAD CIRCUIT NUMBERS.........................................700 TROUBLESHOOTING SECTION.........................................701 COMMON PROBLEMS.................................................701 SUSPENSION CHARGING.........................................701 SYMPTOM TABLE...............................................702 MISSING BODY-UP SIGNAL......................................702 MISSING SPEED SIGNAL........................................703 F-18: R-TERMINAL, OIL PRESSURE SIGNALS......................703 SHORTED 18V SENSOR POWER SUPPLY (930E)......................703 FAULT TREE DIAGNOSIS............................................704 PAYLOAD LIGHTS WON'T ILLUMINATE.............................704 RED, AMBER, OR GREEN PAYLOAD LIGHTS DON'T ILLUMINATE........705 CANNOT DOWNLOAD - PC COMMUNICATIONS.........................706 PC COMMUNICATIONS CONFIGURATION.............................707 F.CAL: PAYLOAD METER WON'T CALIBRATE........................708 F-20: SENSOR POWER FAULT....................................709 F-21 THRU F-28 PRESSURE SENSOR FAULTS.......................711 F-31, F-32: INCLINOMETER....................................713 BODY UP INPUT...............................................715 BRAKE LOCK INPUT............................................716 SPEED SIGNAL................................................717 CONNECTORS AND PRESSURE SENSORS.................................719 REAL-TIME PAYLOAD METER 2 MONITOR PROGRAM.......................722 DATA DEFINITIONS AND COMMENTS...............................723 TRUCK STATUS AND INPUTS.....................................724 MENU FUNCTIONS..............................................725 USING SCOPE.................................................725 LOG FILE INFORMATION........................................725 CONNECTIONS TO PAYLOAD METER 2..............................726 USING SCOPE.....................................................727 MONITORING INPUTS USING SCOPE...............................727 MONITORING SUSPENSION CHARGING USING SCOPE..................727 PRESSURE SENSOR DUMMY LOADS.................................730 GAIN ADJUSTMENT WORKSHEET.......................................731 N. OPERATOR'S CAB...........................................................733 TRUCK CAB...............................................................735 DESCRIPTION.........................................................735 REMOVAL.........................................................736 INSTALLATION....................................................737 CAB DOOR............................................................738 REMOVAL.........................................................738 INSTALLATION....................................................738 DOOR ADJUSTMENT.................................................738 DOOR GLASS REPLACEMENT..........................................741 DOOR HANDLE OR LATCH REPLACEMENT................................745 DOOR AND DOOR HINGE SEAL REPLACEMENT............................746 GLASS REPLACEMENT...................................................747 ADHESIVE BONDED WINDOWS.........................................747 WINDSHIELD AND REAR GLASS REPLACEMENT...........................748 CAB COMPONENTS..........................................................749 WINDSHIELD WIPER....................................................749 WINDSHIELD WASHER...................................................750 OPERATOR COMFORT........................................................751 OPERATOR SEAT.......................................................751 ADJUSTMENT......................................................751 REMOVAL.........................................................751 INSTALLATION....................................................751 HEATER / AIR CONDITIONER................................................752 OPERATION...........................................................752 HEATER COMPONENTS.......................................................753 CIRCUIT BREAKERS....................................................754 HEATER CONTROL COMPONENTS...........................................754 HEATER COIL.........................................................754 FAN MOTOR AND SPEED CONTROL.........................................755 ACTUATORS...........................................................755 FILTER..............................................................755 P. LUBRICATION AND SERVICE..................................................775 LUBRICATION AND SERVICE.................................................777 Q. ALPHABETICAL INDEX.......................................................803 R. SYSTEM SCHEMATICS........................................................807 HYDRAULIC BRAKE SYSTEM SCHEMATIC........................................809 HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE)................................810 POWER AND EXCITATION SCHEMATIC HE376....................................811 24V ELECTRICAL SCHEMATIC HE476 ........................................814 ELECTRICAL SCHEMATIC EH7478 ............................................830
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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