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Komatsu 730E Dump Truck Shop Manual SN A30133-A30180 – PDF DOWNLOAD
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Komatsu 730E Dump Truck Shop Manual
Book Code: CEBM010800
SERIAL NUMBER A30133 – A3an0d u1p 80
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Description
Komatsu 730E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 730E Dump Truck Shop Manual
Brands: Komatsu Equipment Type: Dump Truck Manuals Type: Shop Manual Machine Model: 730E Serial Number: A30133-A30180 Book Code: CEBM010800 Language: English Pages: 832 File Format: Portable Document Format (PDF)
KOMATSU 730E DUMP TRUCK SHOP MANUAL SN A30133-A30180 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 730E Dump Truck Shop Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, 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 infom’ration. 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 US. 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.lbs. (135 Mm) torque- All torque specifications have i 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 Haulpak 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 infomiation which will identify the original manufacturing bill of material forthis unit. This complete number will be necessary for proper ordering of many service parts andlor warranty consideration.
TABLE OF CONTENTS:
Komatsu 730E Dump Truck Shop 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..................216 ELECTRICAL CHECKOUT PROCEDURE...........................................218 G. DRIVE AXLE, SPINDLES AND WHEELS..........................................270 TIRES AND RIMS (G02012).................................................272 FRONT TIRES AND RIMS................................................273 REMOVAL.........................................................273 INSTALLATION....................................................274 REAR TIRES AND RIMS.................................................274 REMOVAL.........................................................274 INSTALLATION....................................................275 RIM.................................................................276 TIRE REMOVAL....................................................276 TIRE INSTALLATION...............................................277 FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)...........................278 WHEEL HUB AND SPINDLE ASSEMBLY......................................278 REMOVAL.........................................................278 INSTALLATION....................................................280 DISASSEMBLY.....................................................280 CLEANING AND INSPECTION.........................................281 ASSEMBLY........................................................281 WHEEL BEARING ADJUSTMENT (TIRE REMOVED).........................283 WHEEL BEARING ADJUSTMENT (TIRE MOUNTED).........................284 STEERING CYLINDERS AND TIE ROD......................................286 REMOVAL.........................................................286 INSTALLATION....................................................286 BEARING REPLACEMENT.............................................286 TOE-IN ADJUSTMENT...................................................288 REAR AXLE HOUSING ATTACHMENT (G04010)...................................290 PIVOT PIN...........................................................290 REMOVAL.........................................................290 INSTALLATION....................................................290 DISASSEMBLY.....................................................291 ASSEMBLY........................................................291 ANTI-SWAY BAR.......................................................293 REMOVAL.........................................................293 INSTALLATION....................................................293 DISASSEMBLY.....................................................293 CLEANING AND INSPECTION.........................................293 ASSEMBLY........................................................293 REAR AXLE HOUSING (G05004)..............................................294 REAR AXLE HOUSING...................................................294 REMOVAL.........................................................294 INSTALLATION....................................................294 WHEEL MOTOR.........................................................294 REMOVAL.........................................................294 CLEANING AND INSPECTION.........................................295 INSTALLATION....................................................295 H. HYDRAIR II SUSPENSIONS...................................................296 FRONT SUSPENSION........................................................298 REMOVAL.............................................................298 INSTALLATION........................................................299 DISASSEMBLY.....................................................302 ASSEMBLY (BEARING RETAINER ONLY)................................303 ASSEMBLY (COMPLETE).............................................304 SUSPENSION PRESSURE TEST............................................305 REAR SUSPENSION.........................................................306 REMOVAL.............................................................306 INSTALLATION........................................................308 DISASSEMBLY.....................................................309 ASSEMBLY........................................................309 SUSPENSION PRESSURE TEST............................................311 OILING AND CHARGING PROCEDURES..........................................312 GENERAL.............................................................312 EQUIPMENT LIST......................................................312 FRONT SUSPENSION....................................................313 FRONT SUSPENSION OILING.........................................313 FRONT SUSPENSION NITROGEN CHARGING..............................314 REAR SUSPENSION.....................................................315 REAR SUSPENSION OILING..........................................315 REAR SUSPENSION NITROGEN CHARGING...............................316 OIL AND NITROGEN SPECIFICATIONS.........................................317 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........................................592 ENVIRONMENTAL IMPACT................................................592 OPERATOR CAB CONDITIONING...........................................593 PRINCIPLES OF REFRIGERATION.........................................593 MAJOR SYSTEM COMPONENTS.............................................595 SYSTEM SERVICING....................................................598 EVACUATING THE SYSTEM...............................................609 SYSTEM TROUBLESHOOTING..............................................610 24 VDC ELECTRIC SUPPLY SYSTEM...........................................620 ELECTRICAL SYSTEM DESCRIPTION.......................................620 BATTERY - MAINTENANCE AND SERVICE...................................620 BATTERY CHARGING SYSTEM.............................................622 GENERAL DESCRIPTION.............................................622 TROUBLESHOOTING PROCEDURES......................................622 NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL..............................630 DIMENSIONS..........................................................631 SPECIFICATIONS......................................................632 SERVICE PARTS LIST..................................................633 EXPLODED VIEW.......................................................634 ON VEHICLE TEST.....................................................635 BENCH TEST..........................................................637 STATIC TESTS........................................................638 ALTERNATOR DISASSEMBLY..............................................641 ALTERNATOR ASSEMBLY.................................................646 SERVICE TOOL INSTRUCTIONS...........................................655 FUEL - WATER SEPARATOR..................................................658 INSTALLATION........................................................658 OPERATION...........................................................658 FILTER SERVICE......................................................659 PAYLOAD METER II - OBWS.................................................660 TABLE OF CONTENTS...................................................660 GENERAL INFORMATION.............................................663 HAUL CYCLES.................................................663 LIGHTS, SWITCHES, AND COMPONENTS................................664 TIPS FOR OPERATION..............................................665 EXTERNAL DISPLAY LIGHTS.........................................665 THEORY OF OPERATION.............................................666 BASIC DESCRIPTION...........................................666 INCLINOMETER................................................666 LINKAGE FACTOR..............................................666 GAIN FACTOR.................................................667 BRAKE FACTOR................................................667 SOURCES OF ERROR............................................667 TYPICAL DATA FROM SERVICE CHECK MODE........................667 EXAMPLE CALCULATION OF PAYLOAD..............................668 VIEWING PAYLOAD CALCULATION INPUTS..........................668 CHECKING THE GAIN...........................................669 ADJUSTING THE GAIN..........................................669 TYPES OF DATA STORED............................................670 CYCLE DATA..................................................670 ENGINE ON / OFF DATA........................................671 FAULT CODES AND WARNING DATA................................671 ENGINE OPERATION............................................672 TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES....................672 OTHER DATA..................................................672 OPERATOR FUNCTIONS..............................................673 USING THE OPERATOR CHECK MODE...............................673 VIEWING THE OPERATOR LOAD COUNTER...........................673 CLEARING THE OPERATOR LOAD COUNTER..........................673 DIMMING THE LIGHTS ON THE DISPLAY...........................673 INITIAL SETUP OF PAYLOAD METER..................................674 SWITCH SETTINGS.............................................674 CHECKING THE OPERATOR CHECK MODE............................675 CHECKING THE SERVICE CHECK MODE.............................675 SETTING "UP:XX".........................................675 SETTING "PL:00".........................................675 CHECKING THE Gt SETTING.....................................676 CHECKING THE INCLINOMETER SETTING...........................676 CALIBRATING A TRUCK.........................................676 DISPLAYS AT START-UP............................................677 SET-UP AND MAINTENANCE..........................................678 SETTING THE SPEED LIMIT.....................................678 SETTING THE OPTION CODE.....................................678 SETTING THE MACHINE ID......................................679 SETTING THE OPERATOR ID.....................................679 SETTING THE TIME AND DATE...................................679 DOWNLOAD OF INFORMATION.........................................680 DISPLAY OF FAULT CODES..........................................680 CHARTS OF FAULT CODES AND OTHER INFORMATION.....................682 MONITORING INPUT SIGNALS........................................684 SERVICE CHECK MODE..............................................684 UP FACTOR - PAYLOAD CALCULATION GAIN............................685 PL MODE - LOAD CALCULATION TIMING...............................685 FINAL GEAR RATION SELECTION.....................................686 BATTERY REPLACEMENT PROCEDURE...................................687 REPLACING THE BATTERY.......................................687 AFTER REPLACING THE BATTERY.................................688 SUSPENSION PRESSURE SENSOR......................................688 REMOVAL.....................................................688 INSTALLATION................................................689 INCLINOMETER....................................................689 REMOVAL.....................................................689 INSTALLATION................................................689 ADJUSTMENT..................................................689 PAYLOAD METER BACK PANEL........................................690 CONNECTIONS (AMP PIN ID)........................................691 PAYLOAD CIRCUIT NUMBERS.........................................692 PAYLOAD METER 2 REINITIALIZATION PROCEDURE......................693 TROUBLESHOOTING SECTION.........................................694 COMMON PROBLEMS.................................................694 SUSPENSION CHARGING.........................................694 SYMPTOM TABLE...............................................695 MISSING BODY-UP SIGNAL......................................695 MISSING SPEED SIGNAL........................................696 F-18: R-TERMINAL, OIL PRESSURE SIGNALS......................696 SHORTED 18V SENSOR POWER SUPPLY (930E)......................696 FAULT TREE DIAGNOSIS............................................697 PAYLOAD LIGHTS WON'T ILLUMINATE.............................697 RED, AMBER, OR GREEN PAYLOAD LIGHTS DON'T ILLUMINATE........698 CANNOT DOWNLOAD - PC COMMUNICATIONS.........................699 PC COMMUNICATIONS CONFIGURATION.............................700 F.CAL: PAYLOAD METER WON'T CALIBRATE........................701 F-20: SENSOR POWER FAULT....................................702 F-21 THRU F-28 PRESSURE SENSOR FAULTS.......................704 F-31, F-32: INCLINOMETER....................................706 BODY UP INPUT...............................................708 BRAKE LOCK INPUT............................................709 SPEED SIGNAL................................................710 CONNECTORS AND PRESSURE SENSORS.................................712 REAL-TIME PAYLOAD METER 2 MONITOR PROGRAM.......................715 DATA DEFINITIONS AND COMMENTS...............................716 TRUCK STATUS AND INPUTS.....................................717 MENU FUNCTIONS..............................................718 USING SCOPE.................................................718 LOG FILE INFORMATION........................................718 CONNECTIONS TO PAYLOAD METER 2..............................719 USING SCOPE.....................................................720 MONITORING INPUTS USING SCOPE...............................720 MONITORING SUSPENSION CHARGING USING SCOPE..................720 PRESSURE SENSOR DUMMY LOADS.................................723 GAIN ADJUSTMENT WORKSHEET.......................................724 N. OPERATOR'S CAB...........................................................726 TRUCK CAB...............................................................728 DESCRIPTION.........................................................728 REMOVAL.........................................................729 INSTALLATION....................................................730 CAB DOOR............................................................731 REMOVAL.........................................................731 INSTALLATION....................................................731 DOOR ADJUSTMENT.................................................731 DOOR GLASS REPLACEMENT..........................................734 DOOR HANDLE OR LATCH REPLACEMENT................................738 DOOR AND DOOR HINGE SEAL REPLACEMENT............................739 GLASS REPLACEMENT...................................................740 ADHESIVE BONDED WINDOWS.........................................740 WINDSHIELD AND REAR GLASS REPLACEMENT...........................741 CAB COMPONENTS..........................................................742 WINDSHIELD WIPER....................................................742 WINDSHIELD WASHER...................................................743 OPERATOR COMFORT........................................................744 OPERATOR SEAT.......................................................744 ADJUSTMENT......................................................744 REMOVAL.........................................................744 INSTALLATION....................................................744 HEATER / AIR CONDITIONER................................................745 OPERATION...........................................................745 HEATER COMPONENTS.......................................................746 CIRCUIT BREAKERS....................................................747 HEATER CONTROL COMPONENTS...........................................747 HEATER COIL.........................................................747 FAN MOTOR AND SPEED CONTROL.........................................748 ACTUATORS...........................................................748 FILTER..............................................................748 OPERATOR CONTROLS.......................................................750 STEERING COLUMN.....................................................750 REMOVAL.........................................................750 INSTALLATION....................................................750 PEDAL CONTROLS......................................................752 SERVICE BRAKE PEDAL.............................................752 DUAL FUNCTION / SINGLE BRAKE PEDAL..............................752 DYNAMIC RETARDING PEDAL.........................................752 THROTTLE PEDAL..................................................752 CONSOLE CONTROLS........................................................753 OVERHEAD CONTROLS, GAUGES...............................................755 INSTRUMENT PANEL........................................................756 INDICATOR LIGHTS........................................................760 CENTRY FUEL SYSTEM......................................................766 DIAGNOSTICS.........................................................766 DETERMINING FAULT CODES.............................................767 P. LUBRICATION AND SERVICE..................................................768 LUBRICATION AND SERVICE.................................................770 SERVICE CAPACITIES..................................................770 HYDRAULIC TANK SERVICE..............................................770 HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS).......................770 COOLANT LEVEL CHECK.................................................771 RADIATOR FILLING PROCEDURE..........................................771 COOLING SYSTEM RECOMMENDATIONS......................................771 LUBRICATION CHART...................................................772 10 HOURS........................................................773 50 HOURS........................................................775 100 HOURS.......................................................776 250 HOURS.......................................................777 500 HOURS....................................................... 0 1000 HOURS...................................................... 0 5000 HOURS...................................................... 0 LINCOLN AUTOMATIC LUBRICATION SYSTEM....................................778 GENERAL DESCRIPTION.................................................778 SYSTEM COMPONENTS...................................................780 SYSTEM OPERATION....................................................781 GENERAL INSTRUCTIONS................................................784 SYSTEM PRIMING..................................................784 LUBRICANT PUMP..................................................784 FILTER AND RESERVOIR............................................785 INJECTORS.......................................................786 SYSTEM CHECK-OUT....................................................787 24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT...................787 PUMP REBUILD........................................................788 DISASSEMBLY.....................................................788 CLEANING AND INSPECTION.........................................788 ASSEMBLY........................................................790 PREVENTATIVE MAINTENANCE PROCEDURE.................................. 0 MOTORIZED WHEEL MAINTENANCE SCHEDULE....................................792 Q. ALPHABETICAL INDEX.......................................................796 R. SYSTEM SCHEMATICS........................................................800 HYDRAULIC BRAKE SYSTEM SCHEMATIC........................................802 HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE)................................803 ELECTRICAL SCHEMATIC....................................................805
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