Komatsu 830E Dump Truck Shop Manual DG734 – PDF DOWNLOAD

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Komatsu 830E Dump Truck Shop Manual DG734 – PDF DOWNLOAD

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Komatsu 830E Dump Truck Shop Manual DG734 – PDF DOWNLOAD

Language : English
Pages :787
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 830E Dump Truck Shop Manual DG734 – PDF DOWNLOAD

SERIAL NUMBERS A30544 – A30606

FOREWORD

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
• All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.
• For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
• This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model.
• The letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 830E Dump Truck Shop Manual DG734 – PDF DOWNLOAD

COVER 1
SECTION A – GENERAL INFORMATION 3
FOREWARD 3
CONTENTS 5
GENERAL INFORMATION INDEX 7
STORAGE AND IDLE MACHINE PREPARATION 47
SHORT TERM IDLE PERIODS 47
PREPARATION FOR STORAGE 48
REMOVAL FROM STORAGE 49
RECONDITIONING AN IDLE VEHICLE 51
ENGINE OPERATION 54
AFTER ENGINE HAS STARTED 55
ENGINE STORAGE-CUMMINS 56
Engine Storage-(Short Term) 56
Prepare the Engine for Short Term Storage 56
Remove the Engine from Short Term Storage 56
Engine Storage- (Long Term) 57
6 Months to 24 Months 57
Prepare the Engine for Long Term Storage 57
Remove the Engine from Long Term Storage 57
ENGINE STORAGE – DETROIT DIESEL 58
Preparing Engine For Storage 58
Temporary Storage (30 Days Or Less) 58
Extended Storage (more Than 30 Days) 58
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE 60
ELECTRIC DRIVE TRUCKS 61
Storage Instructions and Procedures 61
Placing Equipment Into Storage 61
When Storing A Truck That Is Operational 61
When Storing A Truck That Is Not Operational 62
When Storing A Major Component 62
Periodic Inspections 63
Placing Equipment Into Service After Storage 63
When A Truck Is Operational 63
When A Truck Is Not Operational 63
For The First Hour 64
PRESERVATION AND STORAGE ALLISON TRANSMISSION 65
Storage, New Transmission 65
Storage, One Year — Without Oil 65
Storage, One Year With Oil (normally in a vehicle chassis) 65
Restoring Transmission to Service 65
SECTION B – STRUCTURES 67
STRUCTURES INDEX 67
RIGHT HAND DECK 69
Removal 69
Installation 70
CENTER AND LEFT HAND DECK COMPONENTS 70
FUEL TANK 71
Removal 71
Installation 71
SECTION C – ENGINE, FUEL, COOLING AND AIR CLEANER 79
POWER TRAIN INDEX 93
POWER TRAIN 95
ALTERNATOR REMOVAL PROCEDURE 95
Removal (MTU/DDC 4000 Engine) 95
ENGINE/ALTERNATOR MATING 97
General Instructions 97
MEASURING PROCEDURE 97
Joining Alternator and MTU/DDC Engine 99
ENGINE100
Removal100
Service100
Installation100
AIR FILTRATION SYSTEM101
AIR CLEANER101
Operation101
General Service Information101
MAIN FILTER ELEMENT101
Removal101
Installation102
SAFETY FILTER ELEMENT103
Removal103
Installation103
AIR INTAKE TROUBLESHOOTING103
AIR CLEANER ASSEMBLY CLEANING103
Main Filter Cleaning103
Precleaner Section Cleaning104
SECTION D – ELECTRIC SYSTEM (24VDC NON-PROPULSION)107
ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX107
24VDC ELECTRICAL SYSTEM COMPONENTS119
ALARM INDICATING DEVICE (AID)119
Coolant Level/Flasher Card119
Temperature/Latch Card119
Oil Level Card120
Temperature Card120
Hot Switch Inverter Card (Slot 4)120
Hot Switch Inverter Card (Slot 3)120
Diode Matrix Without Sound Card120
Diode Matrix With Sound Card120
BODY-UP SWITCH120
Adjustment121
Service121
HOIST LIMIT SWITCH121
Adjustment121
Service121
BATTERY EQUALIZER122
Troubleshooting122
GROUND LEVEL SHUTDOWN122
24 VOLT RELAY AND DIODE BOARDS123
RELAY BOARDS123
Description123
SERVICE124
RELAY BOARD COMPONENTS125
Relay Board 1 Turn Signal125
Relay Board 2 Payload Meter (Optional)125
Relay Board 3 Stop Lights126
Relay Board 4 Parking Brake126
Relay Board 5 Head Lights126
Relay Board 6 Auxiliary Panel127
DIODE BOARD 1128
Diode Testing128
CIRCUIT BREAKERS128
DDEC ELECTRONIC ENGINE CONTROL INDEX131
DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE133
COMPONENT DESCRIPTION134
Electronic Control Module134
Electronic Unit Nozzles136
System Sensors and Operator Inputs136
ENGINE PROTECTION SYSTEM137
DIAGNOSTICS138
SECTION E – ELECTRICAL PROPULTION AND CONTROL139
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX215
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE219
GENERAL INFORMATION219
COMMUNICATIONS PORT CHECK220
PTU Hookup220
40 SEQUENCE TESTS – (ENGINE NOT ON)221
Preparation and Setup221
CONTROL SYSTEM SELF-TEST222
41 THROTTLE SYSTEM CHECK AND ADJUSTMENT222
42 RETARD SYSTEM CHECK AND ADJUSTMENT223
PTU Setup223
43 REVERSER AND PROPULSION CONTACTORS CHECK224
44 NOT USED225
45 RETARD CONTACTORS OPERATION CHECK225
46 GROUND FAULT SENSING CHECK225
47 GROUND FAULT IN RETARD OPERATION CHECK226
48 OVERRIDE OPERATION CHECK226
49 ANTI-REVERSAL FUNCTION (AR) CHECK227
410 OVERSPEED RETARD OPERATION CHECK227
411 HOIST INTERLOCK OPERATION CHECK228
412 MOTOR BLOWER FAULT LIGHT OPERATION CHECK228
Return to Main Menu228
50 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL229
51 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU229
52 DIGITAL INPUT CHECKS230
53 DIGITAL OUTPUT CHECKS231
60 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL235
61 SETUP ANALOG INPUT MONITOR SCREEN ON PTU235
62 ANALOG INPUT CHECKS236
63 FREQUENCY INPUT CHECKS240
Return to Main Menu241
70 SPEED EVENT CHECKS241
Preparation and Setup241
Setup PTU241
71 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK242
72 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK242
73 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK242
74 OTHER SPEED EVENTS CHECKS242
Return to Main Menu242
80 RETARD SPEED CONTROL SYSTEM CHECK243
Preparation and Setup243
Setup PTU243
81 OVERSPEED PICKUP AND DROPOUT CHECK243
82 RETARD POT MAXIMUM SETTING CHECK243
83 RETARD POT MINIMUM SETTING CHECK243
84 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL244
Return to Main Menu244
90 LOAD TEST USING TRUCK RETARD GRIDS244
Setup and Preparation244
PTU Setup244
91 LOAD TEST245
100 MOTOR FIELD CURRENT CHECK IN RETARDING245
Setup PTU245
101 RETARD CHECK246
110 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT247
111 BRAKE SYSTEM INTERLOCKS CHECK247
Preparation247
112 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT247
113 SYNC TRANSFORMER CHECKOUT248
114 POWER CONTACTOR POSITION SENSOR ADJUSTMENT248
115 BATTERY BOOST ADJUSTMENT248
116 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST248
117 MOTOR ROTATION TEST249
118 GROUND FAULT CHECKS249
120 MISCELLANEOUS CHARTS250
121 WHEEL MOTOR GEAR RATIOS250
122 MAXIMUM ALLOWABLE TRUCK SPEEDS251
123 ENGINE OPTIONS252
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS255
DRIVE AXLE, SPINDLE AND WHEELS INDEX255
TIRES AND RIMS257
FRONT TIRES AND RIMS257
Removal257
Installation258
REAR TIRES AND RIMS259
Removal259
Installation260
RIM261
Tire Removal261
RIM AND TIRE PREPARATION261
LUBRICANTS262
TIRE INSTALLATION262
FRONT WHEEL HUB AND SPINDLE265
WHEEL HUB AND SPINDLE ASSEMBLY265
Removal265
Spindle Pusher Tool Usage266
Installation267
Disassembly269
Cleaning and Inspection269
Assembly270
Wheel Bearing Adjustment (Tire Removed)272
Wheel Bearing Adjustment (Tire mounted)272
STEERING CYLINDERS AND TIE ROD274
Spherical Bearing Wear Limits274
Removal275
Installation275
Bearing Replacement275
TOE-IN ADJUSTMENT277
REAR AXLE HOUSING ATTACHMENT279
PIVOT PIN279
Removal279
Installation279
PIVOT EYE BEARING280
Disassembly280
Assembly280
PIVOT EYE REPAIR281
Removal281
Disassembly281
Assembly281
Installation281
ANTI-SWAY BAR282
Removal282
Installation282
Disassembly282
Cleaning and Inspection282
Assembly282
REAR AXLE HOUSING283
REAR AXLE HOUSING283
Removal283
Installation283
WHEEL MOTOR283
Removal283
Cleaning and Inspection284
Installation284
Maximum Cap Screw Usage284
OILING AND CHARGING PROCEDURE299
GENERAL299
EQUIPMENT LIST299
HYDRAIR® CHARGING KIT299
Installation of Charging Kit299
Removal of Charging Kit300
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS300
FRONT SUSPENSION301
Front Suspension Oiling301
Front Suspension Nitrogen Charging302
REAR SUSPENSION303
Rear Suspension Oiling303
Rear Suspension Nitrogen Charging304
OIL AND NITROGEN SPECIFICATIONS CHART306
SECTION H – HYDRAIR II SUSPENSIONS285
HYDRAIR II SUSPENSIONS INDEX285
SECTION J – BRAKE CIRCUIT307
BRAKE CIRCUIT INDEX307
BRAKE CIRCUIT COMPONENT SERVICE315
BRAKE VALVE315
Rebuild Criteria315
Removal315
DISASSEMBLY318
Cleaning and Inspection320
ASSEMBLY320
Actuator Base Threaded Inserts320
Boot and Cap320
Valve Body Seal Installation321
Regulator Sleeve O-Ring Installation321
Actuator Plunger O-ring Installation321
Assembly of Valve322
DIFFERENTIAL PRESSURE SWITCH323
Disassembly323
Cleaning and Inspection323
Assembly323
VALVE BENCH TEST AND ADJUSTMENT324
Test Set Up Procedure325
Brake Valve Output Pressure Adjustment325
Differential Pressure Switch Test325
Final Test and Adjustment326
Installation Of Brake Pedal Actuator Assembly to Brake Valve327
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal)328
Installation of Retard Pedal To Brake Pedal328
HYDRAULIC BRAKE ACCUMULATORS329
Brake Accumulator Bleed Down Procedure329
Removal329
Installation329
Disassembly329
Cleaning and Inspection330
Assembly331
Charging Procedure332
BRAKE MANIFOLD333
Removal333
Removal333
Installation334
Disassembly334
Cleaning and Inspection334
Assembly334
BRAKE CIRCUIT CHECK-OUT PROCEDURE335
EQUIPMENT REQUIRED337
INITIAL SYSTEM SET-UP338
PARKING BRAKE338
BRAKE SYSTEM CHECK-OUT338
Failure Modes Check-Out339
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING341
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET345
KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET346
ROCKWELL WHEEL SPEED FRONT DISC BRAKES347
BRAKE CALIPER347
Removal347
Installation348
Piston Removal349
Installation349
Caliper Cleaning and Inspection349
BRAKE LINING351
Replacement351
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE352
Front Brake Conditioning352
Temporary Disconnect Procedures For Rear Brakes352
BRAKE BLEEDING PROCEDURES354
ROCKWELL ARMATURE SPEED REAR DISC BRAKES355
REAR BRAKES355
CALIPER, DISC, AND PARKING BRAKE355
Caliper, Disc, And Parking Brake Removal355
Caliper, Disc, And Parking Brake Installation356
CALIPER, DISC, AND PARKING BRAKE REMOVAL358
Caliper, Disc, And Parking Brake Installation359
CALIPER PISTON ASSEMBLY360
Piston Assembly Removal360
Piston Assembly Inspection360
Piston Assembly Installation360
FUNCTIONAL TEST OF PISTON ASSEMBLY361
Return Spring Force361
Built-In Clearance361
Grip Force362
Grip Force Measurement363
Spring Force Measurement364
Disassembly of Piston Assembly365
Assembly of Piston Assembly366
BENCH TEST366
BRAKE LINING367
Replacement367
Brake Pad Conditioning (Burnishing) Procedure369
General369
Conditioning (Burnishing) Rear Brakes369
BLEEDING PROCEDURE370
Temporary Disconnect Procedures for Disabling Front Brakes370
TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Models 630E and 685E Komatsu Trucks371
TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Model 830E Komatsu Trucks371
ROCKWELL DISC PARKING BRAKE373
CALIPER STYLE IDENTIFICATION373
PARK BRAKE CALIPER374
Park Brake Caliper Removal374
Park Brake Caliper Installation374
Parking Brake Adjustment (SCL70)374
Parking Brake Adjustment (SCL15)376
Park Brake Caliper Disassembly377
Cleaning and Inspection378
Park Brake Caliper Assembly379
PARK BRAKE LINING REPLACEMENT379
PARK BRAKE BURNISH PROCEDURE379
Lining Conditioning379
BRAKE BLEEDING PROCEDURE379
SECTION K – AIR SYSTEM381
AIR SYSTEM INDEX381
AIR SYSTEM OPERATION383
AIR SYSTEM COMPONENT REPAIR387
SECTION L – HYDRAULIC SYSTEM393
HYDRAULIC SYSTEM INDEX393
HYDRAULIC CHECK-OUT PROCEDURE503
STEERING AND BRAKE PUMP503
Pressure Check And Adjustment Procedure503
BLEEDDOWN MANIFOLD504
SHOCK & SUCTION VALVES505
Shock & Suction Valve Settings505
LEAKAGE TESTS505
Steering Control Unit & Flow Amplifier506
Bleed Down Manifold507
TROUBLESHOOTING CHART508
TROUBLESHOOTING CHART511
TROUBLESHOOTING CHART514
CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE516
HYDRAULIC SYSTEM FLUSHING PROCEDURE519
SECTION M – OPTIONS AND SPECIAL TOOLS521
OPTIONS AND SPECIAL TOOLS INDEX521
FIRE CONTROL SYSTEM (MANUAL)523
Operation523
Inspection and Maintenance523
Recharging Procedures524
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM525
SYSTEM ADJUSTMENT525
PUMP525
Removal525
Disassembly525
Inspection527
Assembly527
Installation528
BLOWER DRIVE MOTOR528
Removal529
Disassembly529
Inspection Of Parts530
Assembly530
Installation531
BLOWER BEARING REPAIR531
Removal531
Replacement531
Assembly532
AIR CLEANER532
Assembly532
Removal532
Washing Air Cleaner532
Assembly532
WIGGINS QUICK FILL FUEL SYSTEM533
FUEL RECEIVER533
TANK BREATHER VALVE534
Removal534
Installation534
Disassembly534
Assembly534
LEFT SIDE FILL535
BUCKEYE QUICK FUEL SYSTEM537
FUEL TANK BREATHER VALVE537
Maintenance537
Filter Service537
Disassembly537
Inspection537
Assembly537
FUEL RECEIVER538
ENGINE COOLANT HEATER539
Maintenance539
HEATING ELEMENT539
Removal539
Installation539
THERMOSTAT540
Removal540
Installation540
SPECIAL TOOLS541
AIR CONDITIONING SYSTEM547
Environmental Impact547
OPERATOR CAB AIR CONDITIONING548
PRINCIPLES OF REFRIGERATION548
Air Conditioning548
Refrigeration – The Act Of Cooling549
The Refrigeration Cycle549
AIR CONDITIONER SYSTEM COMPONENTS550
Compressor (Refrigerant Pump)550
Service Valves550
Condenser550
Expansion Block Valve551
Evaporator551
ELECTRICAL CIRCUIT552
Thermostat552
Compressor Clutch552
Trinary™ Switch553
SYSTEM SERVICING554
SYSTEM OIL555
Handling and Reusing PAG Oil555
Oil Quantity555
Replacing Oil After Servicing the System555
Setting Up a New Compressor555
REFRIGERANT556
Recycled Refrigerant556
Reclaimed Refrigerant556
Refrigerant Quantity556
R-134a Refrigerant Containers556
SERVICE TOOLS AND EQUIPMENT557
Recovery/Recycle Station557
Leak Detector557
Service Valves558
Vacuum Pump558
Manifold Gauge Set559
Installing Manifold Gauge Set560
Purging Air From Service Hoses561
Stabilizing the AC System562
SYSTEM PERFORMANCE TEST562
SYSTEM LEAK TESTING563
Electronic leak detector563
Tracer dyes563
Soap and water563
SYSTEM REPAIR564
System Cleaning564
Hoses and Fittings564
Lines564
Expansion Valve564
Receiver-Drier565
Thermostat565
Compressor565
Clutch565
Servicing the Compressor Clutch566
Pulley Removal568
Clutch Coil Check568
Pulley Installation568
Clutch Assembly Installation569
RECOVERING AND RECYCLING THE REFRIGERANT570
Performing the Recovery Cycle570
Performing the Recycling Procedure570
Evacuating and Charging the AC System570
EVACUATING THE SYSTEM571
CHARGING THE AC SYSTEM572
TROUBLESHOOTING573
Pre-Diagnosis Checks573
Preparing For Diagnosis573
Preliminary Steps573
System Performance Test573
Diagnosis Of Gauge Readings And System Performance574
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM581
AIR DRYER (AEROFINER III)583
AIR DRYER583
Service583
Indications To Change Desiccant583
Removal584
Installation584
Disassembly584
Assembly585
CHECK VALVE585
Removal585
Installation585
PURGE VALVE & HEATER586
Removal586
Inspection586
Installation586
PAYLOAD METER II – ON BOARD WEIGHING SYSTEM INDEX587
PAYLOAD METER II – ON BOARD WEIGHING SYSTEM589
GENERAL INFORMATION589
Haul Cycles589
LIGHTS, SWITCHES AND COMPONENTS590
TIPS FOR OPERATION591
EXTERNAL DISPLAY LIGHTS591
THEORY OF OPERATION592
Basic Description592
Inclinometer592
Linkage Factor592
Gain Factor593
Brake Lock593
Sources of Error593
Typical Data From Service Check Mode593
Example Calculation of Payload594
Viewing Payload Calculation Inputs594
Checking the Gain595
Adjusting the Gain595
TYPES OF DATA STORED596
Cycle Data596
Engine ON/OFF Data597
Fault Codes and Warning Data597
Engine Operation598
Total Payload and Total Number of Cycles598
Other Data598
OPERATOR FUNCTIONS599
Using the Operator Load Counter599
Viewing the Operator Load Counter599
Clearing the Operator Load Counter599
Dimming the Lights on the Display599
INITIAL SETUP OF PAYLOAD METER600
Switch Settings600
Checking the Operator Check Mode601
Checking the Service Check Mode601
Checking the Gt setting:602
Checking the Inclinometer Settings602
Calibrating a Truck602
DISPLAYS AT START-UP603
Normal Operation603
SETUP AND MAINTENANCE604
Setting The Speed Limit604
Setting the Option Code604
Setting The Machine ID Code605
Setting The Operator ID Code605
Setting The Time and Date605
DOWNLOAD OF INFORMATION606
DISPLAY OF FAULT CODES606
Monitoring Input Signals610
Service Check Mode610
UP FACTOR – PAYLOAD CALCULATION GAIN611
PL MODE -LOAD CALCULATION TIMING611
FINAL GEAR RATIO SELECTION612
BATTERY REPLACEMENT PROCEDURE613
Replacing the Battery613
After Replacing the Battery614
SUSPENSION PRESSURE SENSOR614
Removal614
Installation615
INCLINOMETER615
Removal615
Installation615
Adjustment615
PAYLOAD METER BACK PANEL616
CONNECTIONS617
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE618
PAYLOAD CIRCUIT NUMBERS619
TROUBLESHOOTING620
COMMON PROBLEMS620
Suspension Charging620
Symptom Table621
Missing Body-Up Signal621
Missing Speed Signal622
F-18: Alternator R-Terminal, Oil Pressure Signals622
Shorted 18v Sensor Power Supply (930E)622
FAULT TREE DIAGNOSIS623
Payload Lights Won’t Illuminate623
Red, Amber or Green Payload Light Does Not Illuminate624
Cannot Download – PC Communications625
PC Communications Configuration626
FCAL: Payload Meter Won’t Calibrate627
F-20: Sensor Power Fault628
F-21, F-25: Left Front Pressure Sensor630
F-22, F-26: Right Front Pressure Sensor630
F-23, F-27: Left Rear Pressure Sensor630
F-24, F-28: Right Rear Pressure Sensor630
F-31, F-32: Inclinometer632
Body Up Input634
Brake Lock Input635
Speed Signal636
Adjusting the Speed Sensor636
CONNECTORS AND PRESSURE SENSORS638
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM641
Menu Functions644
Using Scope644
Log File Information644
Connections to Payload Meter II™645
USING SCOPE646
Monitoring Inputs Using Scope646
Monitoring Suspension Charging Using Scope646
Pressure Sensor Dummy Loads649
GAIN ADJUSTMENT WORKSHEET650
SECTION N – OPERATOR’S CAB651
OPERATOR’S CAB INDEX651
OPERATOR’S CAB INDEX651
TRUCK CAB653
Description653
Removal654
Installation655
CAB DOOR656
Removal656
Installation656
Door Adjustment656
Door Jamb Bolt Adjustment656
Door Handle Plunger Adjustment658
Replace Door Glass659
Replace Door Window Regulator663
Replace Door Handle or Latch Assembly663
Door and Door Hinge Seal Replacement664
Door Opening Seal Removal664
Installation664
GLASS REPLACEMENT665
ADHESIVE-BONDED WINDOWS665
Replacement Procedure665
WINDSHIELD & REAR GLASS666
Removal666
Installation667
CAB COMPONENTS669
WINDSHIELD WIPER669
Removal669
Installation669
WINDSHIELD WASHER670
Operation670
Service670
OPERATOR COMFORT671
HEATER/AIR CONDITIONER672
OPERATION672
HEATER COMPONENTS673
CIRCUIT BREAKERS673
HEATER WATER CONTROL SOLENOID673
Test674
HEATER COIL674
FAN MOTOR AND SPEED CONTROL675
Test675
ACTUATORS675
Test675
FILTER675
Service675
AIR CONDITIONER COMPONENTS675
SECTION P – LUBRICATION AND SERVICE703
LUBRICATION AND SERVICE INDEX703
MOTORIZED WHEEL MAINTENANCE SCHEDULE723
AXLE BOX723
MOTORIZED WHEEL MAINTENANCE SCHEDULE724
ARMATURE AREA724
AT TIRE CHANGE – FOR ALL MOTORIZED WHEELS724
MOTORIZED WHEEL MAINTENANCE SCHEDULE725
GENERATOR / ALTERNATOR725
GRID BLOWER MOTOR725
CONTROL EQUIPMENT CHECKS725
MOTORIZED WHEEL MAINTENANCE SCHEDULE726
AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM726
VEHICLE OPERATIONS TESTS726
SECTION Q – ALPHABETICAL INDEX727
ALPHABETICAL INDEX727
SECTION R – SYSTEM SCHEMATICS731
SYSTEM SCHEMATICS INDEX731

IMAGES PREVIEW OF THE MANUAL:

S.M 12/12/24