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Cummins QSK60 Engine Komatsu 930E-2 Dump Truck Shop Manual SN A30181 thru A30223 – PDF DOWNLOAD
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Cummins QSK60 Engine Komatsu 930E-2 Dump Truck Shop Manual SN A30181 thru A30223 – PDF DOWNLOAD
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Description
Cummins QSK60 Engine Komatsu 930E-2 Dump Truck Shop Manual SN A30181 thru A30223 – PDF DOWNLOAD
FILE DETAILS:
Cummins QSK60 Engine Komatsu 930E-2 Dump Truck Shop Manual SN A30181 thru A30223 – PDF DOWNLOAD
Language : English
Pages : 739
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Cummins QSK60 Engine Komatsu 930E-2 Dump Truck Shop Manual SN A30181 thru A30223 – PDF DOWNLOAD
FOREWORD:
- This Shop Manual is written for use by the service technician and is designed to help the
technician become fully knowledgeable of the truck and all its systems in order to keep it
running and in production. All maintenance personnel should read and understand the
materials in this manual before performing maintenance and/or operational checks on the truck. All
safety notices, warnings and cautions should be understood and followed when accomplishing repairs
on the truck. - The first section covers component descriptions, truck specifications and safe work practices, as
well as other general information. The major portion of the manual pertains to disassembly, service
and reassembly. Each major serviceable area is dealt with individually. For example: The
disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true
of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
Disassembly should be carried only as far as necessary to accomplish needed repairs. - The illustrations used in this manual are, at times, typical of the component shown and may not
necessarily depict a specific model. - This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references
to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated
position, unless specifically stated otherwise. - Standard torque requirements are shown in torque charts in the general information section and
individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m)
torque. All torque specifications have ± 10% tolerance unless otherwise specified. - A Product Identification plate is normally located on the truck frame in front of the right side
front wheel and designates the Truck Model Number, Product Identification Number (vehicle
serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. - The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three
numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the
letter “E” designates an Electrical propulsion system. - The Product Identification Number (vehicle serial number) contains information which will identify
the original manufacturing bill of material for this unit. This complete number will be necessary
for proper ordering of many service parts and/or warranty consideration.
TABLE OF CONTENTS:
Cummins QSK60 Engine Komatsu 930E-2 Dump Truck Shop Manual SN A30181 thru A30223 – PDF DOWNLOAD
MAIN MENU................................................................... 0 COVER....................................................................... 1 FOREWARD.................................................................... 5 CONTENTS.................................................................... 7 A. GENERAL INFORMATION...................................................... 9 TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS............................ 11 GENERAL SAFETY AND TRUCK OPERATION...................................... 15 WARNINGS AND CAUTIONS................................................... 47 CHARTS ANS TABLES....................................................... 55 STORAGE PROCEDURES...................................................... 61 B. STRUCTURES............................................................... 77 STRUCTURAL COMPONENTS................................................... 79 PREPARATION......................................................... 79 GRILLE, HOOD AND LADDER............................................. 80 DECKS............................................................... 81 RIGHT DECK AND COMPONENTS....................................... 81 LEFT DECK....................................................... 82 CENTER DECK..................................................... 82 DUMP BODY............................................................... 83 DUMP BODY........................................................... 83 REMOVAL......................................................... 83 INSTALLATION.................................................... 84 BODY PADS........................................................... 85 BODY GUIDE.......................................................... 86 HOIST LIMIT SWITCH.................................................. 86 BODY UP SWITCH...................................................... 86 BODY-UP RETENTION CABLE............................................. 86 ROCK EJECTORS....................................................... 87 FUEL TANK............................................................... 89 FUEL TANK........................................................... 89 REMOVAL......................................................... 90 INSTALLATION.................................................... 90 REPAIR.......................................................... 90 CLEANING........................................................ 90 VENT................................................................ 91 FUEL GAUGE SENDER................................................... 91 REMOVAL......................................................... 91 INSTALLATION.................................................... 91 C. ENGINE................................................................... 93 POWER MODULE............................................................ 95 PREPARATION......................................................... 96 REMOVAL......................................................... 99 INSTALLATION....................................................101 COOLING SYSTEM..........................................................103 RADIATOR............................................................103 REMOVAL.........................................................103 INSTALLATION....................................................105 RADIATOR FILL PROCEDURE.............................................106 TROUBLESHOOTING.....................................................106 POWER TRAIN.............................................................107 ALTERNATOR REMOVAL PROCEDURE........................................107 REMOVAL.........................................................107 ENGINE/ALTERNATOR MATING............................................109 JOINING ALTERNATOR AND ENGINE...................................111 ENGINE..............................................................112 REMOVAL ........................................................112 INSTALLATION....................................................112 AIR FILTRATION SYSTEM...................................................113 AIR CLEANERS........................................................113 FILTER ELEMENT REPLACEMENT......................................114 MAIN FILTER ELEMENT CLEANING....................................115 PRECLEANER SECTION..................................................116 CLEANING PRECLEANER TUBES.......................................116 AIR INTAKE TROUBLESHOOTING..........................................117 D. ELECTRICAL SYSTEM (24VDC NON-PROPULSION).................................119 24VDC ELECTRIC SUPPLY SYSTEM............................................121 ELECTRICAL SYSTEM DESCRIPTION.......................................121 BATTERIES.......................................................121 BATTERY CHARGING ALTERNATOR (REFER TO SECTION "M")..............123 BATTERY SUPPLY SYSTEM...............................................123 BATTERY BOX.....................................................123 BATTERY CONTROL BOX.............................................123 SYSTEM BATTERY STARTER DISCONNECT RELAY.....................123 BATTERY DISCONNECT SWITCHES.................................124 24 VDC AUXLIARY BATTERY CONNECTORS..........................124 BATTERY EQUALIZER...........................................125 24 VDC ELECTRICAL SYSTEM COMPONENTS.....................................127 PASSENGER SEAT BASE COMPARTMENT.....................................127 5 MINUTE IDLE TIMER COMPONENTS..................................127 ALARM INDICATING DEVICE (AID SYSTEM)............................129 ELECTRICAL INTERFACE CABINET........................................132 TRUCK CONTROL INTERFACE PANEL (TCI).............................132 DIODE BOARD (DBI)...............................................134 DIODE TESTING...............................................134 RELAY BOARDS....................................................135 SERVICE.....................................................135 BODY UP SWITCH..................................................139 HOIST LIMIT SWITCH..............................................140 CIRCUIT BREAKER CHART...........................................141 E. ELECTRICAL PROPULSION SYSTEM.............................................143 ELECTRICAL PROPULSION SYSTEM COMPONENTS.................................145 GENERAL SYSTEM DESCRIPTION..........................................145 SYSTEM COMPONENTS...............................................147 DID PANEL FAULT CODES...........................................149 PSC SOFTWARE FUNCTIONS..........................................174 PROPULSION SYSTEM COMPONENT ABBREVIATIONS.......................185 ELECTRIC ACCELERATOR AND RETARD PEDALS..........................195 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE...........................197 AC DRIVE SYSTEM MAINTENANCE.........................................197 TRUCK SHUTDOWN PROCDURES........................................197 NORMAL SHUTDOWN.............................................198 SHUTDOWN AFTER A SYSTEM FAILURE.............................199 SYSTEM CHECKOUT (RELEASE 17 SOFTWARE)...............................200 BATTERY AND CONTROL CHECKS, BATTERY POWER OFF...................200 BATTERY AND CONTROL CHECKS, BATTERY POWER ON....................203 MEMORY BACKUP BATTERY REPLACEMENT...........................206 TCI PROGRAMMING.................................................206 PSC PROGRAMMING.................................................207 INVERTER PROGRAMMING............................................207 TRUCK CONTROL INTERFACE (TCI) CHECKOUT..........................208 PROPULSION SYSTEM CONTROLLER (PSC) CHECKOUT.....................214 LOAD TESTING....................................................222 ON-BOARD LOAD TESTING.......................................226 PVM OPTIMUM LOAD CURVE HANDSHAKING TROUBLESHOOTING..........231 MISCELLANEOUS COMPONENT REPAIR......................................232 TROUBLESHOOTING PHASE MODULES AND CHOPPER MODULES...............232 PHASE MODULE REMOVAL AND SNUBBER RESISTER REPLACEMENT.......232 AUXILIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING ................234 AUXILIARY INVERTER (CONTROLLER) TROUBLESHOOTING.............237 AUXILIARY SNUBBER PANEL TROUBLESHOOTING.....................238 IGBT TROUBLESHOOTING........................................239 G. REAR AXLE, SPINDLES AND WHEELS...........................................241 TIRES AND RIMS..........................................................243 FRONT TIRES AND RIMS................................................244 REMOVAL.........................................................244 INSTALLATION....................................................245 REAR TIRES AND RIMS.................................................245 REMOVAL.........................................................245 INSTALLATION....................................................246 RIM.................................................................248 TIRE REMOVAL....................................................248 TIRE INSTALLATION...............................................249 FRONT WHEEL HUB AND SPINDLE.............................................251 WHEEL HUB AND SPINDLE...............................................251 REMOVAL.........................................................251 INSTALLATION....................................................254 DISASSEMBLY.....................................................255 CLEANING AND INSPECTION.........................................255 ASSEMBLY........................................................257 WHEEL BEARING ADJUSTMENT........................................257 SEAL ASSEMBLY GAP CHECK.........................................259 STEERING CLYINDERS AND TIE ROD......................................259 REMOVAL.........................................................260 INSTALLATION....................................................261 BEARING REPLACEMENT.............................................261 TOE-IN ADJUSTMENT...................................................262 REAR AXLE HOUSING MOUNTING ATTACHMENT...................................263 PIVOT PIN...........................................................263 ANTI-SWAY BAR.......................................................266 REAR AXLE HOUSING.......................................................267 REAR AXLE HOUSING...................................................267 ELECTRIC WHEEL MOTORS...............................................270 H. HYDRAIR II SUSPENSIONS...................................................273 FRONT SUSPENSION........................................................275 FRONT SUSPENSION....................................................275 REMOVAL.........................................................275 INSTALLATION....................................................276 "TURN OF THE NUT" TIGHTENING PROCEDURE..............................278 MINOR REPAIR (LOWER BEARING AND SEALS)..............................279 MAJOR SUSPENSION REBUILD............................................280 DISASSEMBLY.....................................................280 ASSEMBLY........................................................281 REAR SUSPENSION.........................................................283 REAR SUSPENSION.....................................................283 REMOVAL.........................................................283 INSTALLATION....................................................285 DISASSEMBLY.................................................286 ASSEMBLY....................................................286 OILING AND CHARGING PROCEDURES..........................................289 GENERAL.............................................................289 EQUIPMENT LIST......................................................289 FRONT SUSPENSION....................................................290 FRONT SUSPENSION OILING.........................................290 FRONT SUSPENSION NITROGEN CHARGING..............................291 REAR SUSPENSION.....................................................292 REAR SUSPENSION OILING..........................................292 REAR SUSPENSION NITROGEN CHARGING...............................293 OIL AND NITROGEN SPECIFICATIONS.....................................294 J. BRAKE SYSTEM.............................................................295 BRAKE CIRCUIT...........................................................297 SERVICE BRAKE CIRCUIT OPERATION.....................................297 SECONDARY BRAKING AND AUTOMATIC APPLY...............................299 PARKING BRAKE CIRCUIT...............................................299 BRAKE LOCK CIRCUIT..................................................300 WARNING CIRCUIT.....................................................300 BRAKE VALUE CUT-AWAY................................................301 BRAKE CIRCUIT COMPONENT SERVICE.........................................303 BRAKE VALVE.........................................................303 REMOVAL.........................................................304 INSTALLATION....................................................304 DISASSEMBLY.................................................305 CLEANING AND INSPECTION.....................................308 ASSEMBLY....................................................308 DIFFERNTIAL PRESSURE SWITCH.....................................311 VALVE BENCH TEST AND ADJUSTMENT.................................312 DIFFERNTIAL PRESSURE SWITCH ADJUSTMENT......................313 INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE....315 INSTALLATION OF RETARD PEDAL TO BRAKE VALVE.....................315 DUAL RELAY VALVE....................................................317 DUAL RELAY VALVE................................................317 DISASSEMBLY.................................................319 CLEANING AND INSPECTION.....................................319 ASSEMBLY....................................................319 DIFFERENTIAL PRESSURE SWITCH....................................320 VALVE TEST AND ADJUSTMENT.......................................321 DIFFERENTIAL PRESSURE SWITCH ADJUSTMENT.....................323 HYDRAULIC BRAKE ACCUMULATORS........................................324 BRAKE ACCUMULATOR BLEEDDOWN PROCEDURE...........................324 ACCUMULATORS (HYDRAULIC COMPONENTS CABINET).....................324 REMOVAL.....................................................324 INSTALLATION................................................324 DISASSEMBLY.................................................324 CLEANING AND INSPECTION.....................................325 ASSEMBLY....................................................326 CHARGING PROCEDURE..............................................327 ACCUMULATORS (FRAME MOUNTED)....................................328 REMOVAL.....................................................328 INSTALLATION................................................328 DISASSEMBLY.................................................329 CLEANING AND INSPECTION.....................................329 ASSEMBLY....................................................330 ACCUMULATOR CHARGING PROCEDURE..................................331 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)....................332 REMOVAL.........................................................332 INSTALLATION....................................................332 DISASSEMBLY AND ADJUSTMENT......................................333 POTENTIOMETER CHECKS............................................333 ASSEMBLY........................................................333 BRAKE CIRCUIT CHECKOUT PROCEDURE........................................335 BRAKE CIRCUIT CHECKOUT PROCEDURE....................................335 EQUIPMENT REQUIRED..............................................337 INITIAL SYSTEM SETUP............................................338 BRAKE SYSTEM CHECKOUT...............................................339 FAILURE MODES CHECK-OUT.............................................340 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...........................343 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET...................347 WET DISC BRAKE ASSEMBLY (FRONT AND REAR)................................349 OPERATION...........................................................349 MAINTENANCE.........................................................350 BRAKE DISC WEAR INDICATOR.......................................350 BRAKE REBUILD.......................................................352 BRAKE REBUILD...................................................352 DISASSEMBLY.................................................352 CLEANING AND INSPECTION.....................................355 ASSEMBLY....................................................356 SEAL GAP ADJUSTMENT (REAR BRAKE ASSEMBLY).......................358 FLOATING RING SEAL ASSEMBLY/INSTALLATION........................359 WET DISC BRAKE BLEEDING PROCEDURE...................................362 PARKING BRAKE...........................................................363 OPERATION...........................................................363 MAINTENANCE.........................................................364 INSPECTION......................................................364 REMOVAL.....................................................364 INSTALLATION................................................365 DISASSEMBLY.................................................366 CLEANING AND INSPECTION.....................................366 ASSEMBLY....................................................366 PARKING BRAKE BLEEDING PROCEDURE....................................368 L. HYDRAULIC SYSTEM.........................................................369 HYDRAULIC SYSTEM........................................................371 HOIST CIRCUIT OPERATION.............................................372 STEERING CIRCUIT....................................................374 DISC BRAKE COOLING SYSTEM...........................................376 HYDRAULIC SYSTEM COMPONENT REPAIR.......................................379 HOIST PUMP..........................................................379 HOIST PUMP......................................................379 REMOVAL.....................................................379 INSTALLATION................................................381 DISASSEMBLY.................................................382 ASSEMBLY....................................................386 TROUBLESHOOTING GUIDE...............................................391 HYDRAULIC TANK......................................................392 FILLING INSTRUCTIONS............................................392 REMOVAL.....................................................392 INSTALLATION................................................393 STRAINERS.......................................................393 BREATHERS.......................................................394 STEERING CIRCUIT........................................................395 STEERING CIRCUIT OPERATION..........................................395 COMPONENT DESCRIPTION...............................................396 STEERING CONTROL VALVE..........................................396 BLEED DOWN MANIFOLD VALVE.......................................397 ACCUMULATORS....................................................399 FLOW AMPLIFIER..................................................400 STEERING PUMP...................................................410 STEERING CONTROL UNIT...................................................415 STEERING CONTROL UNIT...............................................415 REMOVAL.........................................................415 INSTALLATION....................................................415 REBUILD PROCEDURE...................................................416 DISASSEMBLY.....................................................416 CLEANING AND INSPECTION.........................................417 ASSEMBLY........................................................419 STEERING CIRCUIT COMPONENT REPAIR.......................................423 BLEEDDOWN MANIFOLD VALVE............................................423 STEERING ACCUMULATORS...............................................424 STEERING ACCUMULATOR CHARGING PROCEDURE.............................427 FLOW AMPLIFIER......................................................428 STEERING CYLINDERS..................................................432 STEERING AND BRAKE PUMP.............................................434 REMOVAL.........................................................434 INSTALLATION....................................................434 DISASSEMBLY.....................................................436 ASSEMBLY........................................................442 TROUBLESHOOTING CHART...............................................445 HOIST CIRCUIT ..........................................................451 HOIST CIRCUIT OPERATION.............................................451 COMPONENT DESCRIPTION...............................................452 HOIST CIRCUIT OPERATION.............................................455 HOIST CIRCUIT COMPONENT REPAIR..........................................467 HOIST VALVE.........................................................467 HOIST PILOT VALVE...................................................475 HOIST CYLINDERS.....................................................478 DISABLED TRUCK DUMPING PROCEDURE....................................486 HYDRAULIC SYSTEM FILTERS................................................487 HOIST CIRCUIT FILTER................................................487 STEERING CIRCUIT FILTER.............................................489 INDICATOR SWITCH................................................490 HYDRAULIC CHECK-OUT PROCEDURE...........................................493 STEERING CIRCUIT CHECK-OUT AND ADJUSTMENT PROCEDURE.................493 PUMP PRESSURE CONTROL ADJUSTMENTS...............................494 STEERING CONTROL UNIT FLOW AMPLIFIER LEAKAGE TEST...............495 SHOCK AND SUCTION VALVES........................................497 HOIST SYSTEM RELEIF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.......498 BRAKE COOLING CIRCUIT TEST......................................498 POWER UP RELIEF PRESSURE TEST...................................499 POWER DOWN RELIEF PRESSURE TEST.................................500 HYDRAULIC SYSTEM FLUSHING PROCEDURE.................................502 CHECK-OUT PROCEDURE DATA SHEET......................................505 M. OPTIONS AND SPECIAL TOOLS................................................507 FIRE CONTROL SYSTEMS....................................................509 CHECKFIRE ELECTRIC DETECTION & ACTUATION SYSTEM - SERIES 1..........509 ANSULFIRE CONTROL SYSTEM, MANUAL....................................519 OPERATION.......................................................519 INSPECTION AND MAINTENANCE......................................519 RECHARGING PROCEDURES...........................................520 WIGGINS QUICK FILL FUEL SYSTEM..........................................521 FUEL RECEIVER.......................................................521 TANK BREATHER VALVE.................................................522 LEFT SIDE FILL......................................................523 SPECIAL TOOL GROUP......................................................525 HEATER/AIR CONDITIONING SYSTEM - 134A REFRIGERANT.......................533 ENVIORNMENTAL IMPACT...............................................533 OPERATOR CAB CONDITIONING...........................................534 PRINCIPLES OF REFRIGERATION.........................................534 MAJOR SYSTEM COMPONENTS.............................................536 SYSTEM SERVICING....................................................539 EVACUATING THE SYSTEM...............................................550 SYSTEM TROUBLESHOOTING..............................................551 24 VDC ELECTRIC SUPPLY SYSTEM - NIEHOFF 240 AMP. ALTERNATOR (M13002)....561 ELECTRICAL SYSTEM DESCRIPTION.......................................561 BATTERY - MAINTENANCE AND SERVICE...................................561 BATTERY CHARGING SYSTEM (NIEHOFF 240 AMP. ALTERNATOR................563 GENERAL DESCRIPTION.............................................563 TROUBLESHOOTING PROCEDURES (ON TRUCK)...........................563 NIEHOFF 240 AMP. ALTERNATOR OVERHAUL MANUAL (M13003)....................571 DIMENSIONS..........................................................572 SPECIFICATIONS......................................................573 SERVICE PARTS LIST..................................................574 EXPLODED VIEW.......................................................575 ON VEHICLE TEST.....................................................576 BENCH TEST..........................................................578 STATIC TESTS........................................................579 ALTERNATOR DIASSEMBLY...............................................582 ALTERNATOR ASSEMBLY.................................................587 SERVICE TOOL INSTRUCTIONS...........................................596 PAYLOAD METER II-ON-BOARD WEIGHING SYSTEM...............................599 TABLE OF CONTENTS...................................................599 GENERAL INFORMATION.............................................601 LIGHTS, SWITCHES AND COMPONENTS.................................602 TIPS FOR OPERATION..............................................603 EXTERNAL DISPLAY LIGHTS.........................................603 THEORY OF OPERATION.............................................604 BASIC DESCRIPTION...........................................604 LINKAGE FACTOR..............................................604 BRAKE LOCK..................................................605 SOURCES OF ERROR............................................605 TYPICAL DATA FROM SERVICE CHECK MODE........................605 EXAMPLE CALCULATION OF PAYLOAD..............................606 CALCULATION OF THE CALIBRATION LOAD.........................606 TYPES OF DATA STORED...........................................607 CYCLE DATA..................................................607 ENGINE ON/OFF DATA..........................................608 FAULT CODES.................................................608 ENGINE OPERATION............................................609 TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES....................609 OTHER DATA..................................................609 OPERATOR FUNCTIONS..............................................610 USING THE OPERATOR LOAD COUNTER.............................610 DESCRIPTION.............................................610 VIEWING THE OPERATOR LOAD COUNTER.......................610 CLEARING THE OPERATOR LOAD COUNTER......................610 DIMMING THE LIGHTS ON THE DISPLAY...........................610 INITIAL SETUP OF PAYLOAD METER..................................611 SWITCH SETTINGS.............................................611 CHECKING THE OPERATOR CHECK MODE............................611 CHECKING THE SERVICE CHECK MODE.............................612 SETTING "UP:00".........................................612 SETTING "PL:00".........................................612 CHECKING THE Gt SETTING.....................................612 CHECKING THE INCLINOMETER SETTINGS..........................612 CALIBRATING A TRUCK.........................................613 DISPLAY AT START-UP.............................................614 SETUP AND MAINTENANCE...........................................615 SETTING THE SPEED LIMIT.....................................615 SETTING THE OPTION CODE.....................................615 SETTING THE MACHINE I.D....................................615 SETTING THE OPERATOR I.D....................................616 SETTING THE TIME AND DATE...................................616 DOWNLOAD OF PAYLOAD AND FAULT CODES.............................616 DISPLAY OF FAULT CODES..........................................617 CHARTS OF ERROR CODES AND OTHER INFORMATION.....................618 MONITORING INPUT SIGNALS....................................620 SERVICE CHECK MODE..........................................620 UP FACTOR - PAYLOAD CALCULATION GAIN........................621 PL MODE - LOAD CALCULATION TIMING...........................621 FINAL GEAR RATIO SELECTION......................................622 BATTERY REPLACEMENT PROCEDURE...................................623 REPLACING THE BATTERY.......................................623 AFTER REPLACING THE BATTERY.................................624 SUSPENSION PRESSURE SENSOR......................................624 REMOVAL.....................................................624 INSTALLATION................................................625 INCLINOMETER....................................................625 REMOVAL.....................................................625 INSTALLATION................................................625 SCOREBOARD......................................................626 DESCRIPTION.................................................626 MAKING CONNECTIONS..........................................626 WIRING DIAGRAM..............................................627 NORMAL OPERATION OF THE SCOREBOARD..........................628 PAYLOAD METER BACK PANEL........................................628 CONNECTIONS (AMP PIN IDENTIFICATION)........................629 PAYLOAD CIRCUIT NUMBERS.........................................630 PAYLOAD METER II RE-INITIALIZATION PROCEDURE....................631 N. OPERATOR'S CAB...........................................................633 TRUCK CAB...............................................................635 TRUCK CAB...........................................................635 DESCRIPTION.....................................................635 PREPARATION FOR REMOVAL.............................................636 REMOVAL.........................................................636 INSTALLATION....................................................638 CAB DOOR............................................................638 REMOVAL.........................................................638 INSTALLATION....................................................638 DOOR ADJUSTMENT.................................................639 REPLACE DOOR GLASS..............................................641 GLASS REPLACEMENT...................................................647 CAB COMPONENTS..........................................................649 WINDSHEILD WIPER....................................................649 WINDSHIELD WASHER...................................................650 HEATER/AIR CONDITIONER..............................................651 OPERATOR COMFORT........................................................655 OPERATOR SEAT.......................................................655 ADJUSTMENT......................................................655 REMOVAL.........................................................655 INSTALLATION....................................................655 HEATER/AIR CONDITIONER..............................................656 OPERATION.......................................................656 HEATER COMPONENTS...................................................657 CIRCUIT BREAKERS................................................657 HEATER CONTROL COMPONENTS.......................................657 HEATER COIL.....................................................657 FAN MOTOR AND SPEED CONTROL.....................................658 ACTUATORS.......................................................658 FILTER..........................................................658 OPERATOR CONTROLS.......................................................661 STEERING COLUMN.....................................................661 REMOVAL.........................................................661 INSTALLATION....................................................661 STEERING WHEEL AND CONTROLS.........................................663 DYNAMIC RETARDING...................................................663 CENTER CONSOLE......................................................667 INSTRUMENT PANEL AND INDICATOR LIGHTS...............................671 PANEL GAUGES, INDICATORS AND CONTROLS...............................672 STATUS/WARNING INDICATOR LIGHT SYMBOLS..............................679 P. LUBRICATION AND SERVICE..................................................687 LUBRICATION AND SERVICE.................................................689 LUBRICATION AND SERVICE.............................................689 SERVICE CAPACITIES..............................................689 HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS)...................689 COOLANT LEVEL CHECK.............................................690 RADIATOR FILLING PROCEDURE......................................690 ANTI-FREEZE SPECIFICATIONS......................................690 LUBRICATION CHART (OIL & GREASE SPECIFICATIONS......................691 10 HOURS............................................................692 50 HOURS............................................................694 100 HOURS...........................................................695 250 HOURS...........................................................696 500 HOURS...........................................................698 1000 HOURS..........................................................699 2500 HOURS..........................................................700 5000 HOURS..........................................................700 LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)......................701 LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)..................701 GENERAL DESCRIPTION.............................................701 SYSTEM COMPONENTS...............................................703 SYSTEM OPERATION................................................704 INJECTOR OPERATION..............................................706 GENERAL INSTRUCTIONS............................................707 LUBRICANT REQUIRED..........................................707 SYSTEM PRIMING..............................................707 LUBRICANT PUMP..............................................707 INJECTORS.......................................................708 SYSTEM CHECKOUT ................................................708 LUBRICATION CYCLE TIMER CHECK...................................709 FILTER ASSEMBLY.................................................709 PUMP REBUILD....................................................710 SYSTEM TROUBLESHOOTING CHART....................................713 PREVENTATIVE MAINTENANCE PROCEDURES.............................716 Q. ALPHABETICAL INDEX.......................................................717 R. SYSTEM SCHEMATICS........................................................721 HYDRAULIC BRAKE SYSTEM SCHEMATIC........................................722 HYDRAULIC SUPPLY & BRAKE COOLING SCHEMATIC..............................723 ELECTRICAL SCHEMATIC....................................................724
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