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KOMATSU 330M DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10190 – A10211) KOMATSU 330M – PDF DOWNLOAD
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- KOMATSU 330M DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL N:A10190 – A10211
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Description
KOMATSU 330M DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10190 – A10211) KOMATSU 330M
KOMATSU 330M DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10190 – A10211) KOMATSU 330M – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 330M DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10190 – A10211) KOMATSU 330M
- This 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 upright in front of the left 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 HAULPAK® Model designation consists of three numbers and one letter (i.e. 330M). 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. 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.
TABLE OF CONTENTS:
KOMATSU 330M DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10190 – A10211) KOMATSU 330M
MAIN MENU.............................................................................................................. 0 COVER.................................................................................................................. 1 TABLE OF CONTENTS...................................................................................................... 5 A - GENERAL INFORMATION................................................................................................ 7 MAJOR COMPONENTS & SPECIFICATIONS.................................................................................. 9 GENERAL SAFETY..................................................................................................... 13 WARNINGS & CAUTIONS................................................................................................ 43 STANDARD CHARTS & TABLES........................................................................................... 51 STANDARD VALUE TABLES.............................................................................................. 57 B - STRUCTURES......................................................................................................... 75 GRILLE AND HOOD.................................................................................................... 77 DECKS.............................................................................................................. 77 LEFT DECK & CAB.................................................................................................... 78 Removal........................................................................................................ 78 Installation................................................................................................... 78 RIGHT DECK STRUCTURE............................................................................................... 79 Removal........................................................................................................ 79 Installation................................................................................................... 79 CENTER DECK STRUCTURE.............................................................................................. 80 Removal........................................................................................................ 80 Installation................................................................................................... 80 DUMP BODY - REMOVAL................................................................................................ 81 DUMP BODY - INSTALLATION........................................................................................... 82 BODY PADS.......................................................................................................... 83 Removal........................................................................................................ 83 Installation................................................................................................... 83 Adjustment..................................................................................................... 83 BODY GUIDE......................................................................................................... 84 BODY PIN........................................................................................................... 84 ROCK EJECTORS...................................................................................................... 85 Rock Ejectors - Inspection..................................................................................... 85 FUEL TANK.......................................................................................................... 87 Removal........................................................................................................ 87 Installation................................................................................................... 88 Cleaning....................................................................................................... 88 VENT............................................................................................................... 88 QUICK FUEL OPTION.................................................................................................. 88 C - ENGINE, RADIATOR & AIR CLEANER..................................................................................... 89 RADIATOR........................................................................................................... 91 Removal........................................................................................................ 91 Service........................................................................................................ 93 Installation................................................................................................... 93 BRAKE OIL COOLER................................................................................................... 94 Removal........................................................................................................ 94 Installation................................................................................................... 94 FAN................................................................................................................ 94 Removal........................................................................................................ 94 Installation................................................................................................... 94 FAN BELT........................................................................................................... 95 Removal........................................................................................................ 95 Installation................................................................................................... 95 ENGINE............................................................................................................. 97 Removal........................................................................................................ 97 Installation...................................................................................................100 DRIVE LINE ADAPTER.................................................................................................101 Removal........................................................................................................101 Installation...................................................................................................102 Repair.........................................................................................................103 AIR FILTRATION SYSTEM..............................................................................................105 AIR CLEANER....................................................................................................105 Service Checks.............................................................................................105 Filter Element Replacement.................................................................................105 MAIN FILTER ELEMENT................................................................................................107 Main Filter Element Cleaning...................................................................................107 Air Intake Troubleshooting.....................................................................................108 D - ELECTRICAL SYSTEM..................................................................................................109 24VDC ELECTRICAL SUPPLY SYSTEM.....................................................................................111 Electrical System Description..................................................................................111 Battery........................................................................................................111 Service....................................................................................................111 Storage....................................................................................................111 Maintenance & Troubleshooting..............................................................................112 Spillage...................................................................................................113 Battery Charging Alternator....................................................................................113 Operation..................................................................................................114 Engine Prelube System..........................................................................................115 Design.....................................................................................................115 Operation..................................................................................................115 Troubleshooting............................................................................................117 24VDC ELECTRICAL SYSTEM COMPONENTS.................................................................................123 Vehicle Monitor System.........................................................................................123 Vehicle Monitor Panel......................................................................................126 Sensors & Switches.........................................................................................126 Monitor Panel Displays ........................................................................................128 Instrument Panel Indicators, Test Switch.......................................................................132 Electronic Accelerator Pedal System............................................................................134 AISS...........................................................................................................135 Transmission Controller........................................................................................136 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................139 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...................................................................140 Points To Remember When Handling Electric Equipment............................................................140 Handling Of Controller Boxes...................................................................................145 Precautions when performing arc welding on the truck...........................................................145 Points to remember when troubleshooting electric circuits......................................................145 Points to remember when handling hydraulic equipment...........................................................145 CHECKS BEFORE TROUBLESHOOTING......................................................................................148 TYPE OF CONNECTOR & POSITION OF INSTALLATION.......................................................................150 FOR ARSC (AUTOMATIC RETARDER SPEED CONTROL)........................................................................155 CONNECTOR PIN ALLOCATION CHART.....................................................................................156 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.........................................................................161 EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM.................................................171 Explanation of functions.......................................................................................171 Explanation of self-diagnostic display functions...............................................................171 Checking operation of electrical system........................................................................173 MONITOR PANEL ACTION CODES & SERVICE MODE..........................................................................177 Outline........................................................................................................177 Action Code Display............................................................................................177 Service Mode...................................................................................................178 Method of deleting data from memory............................................................................186 Precautions when operating service mode........................................................................186 Table 1 Bit Numbers............................................................................................189 Brake Air Pressure Sensor......................................................................................190 SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL & CONTROLLERS.....................................................191 Monitor Panel..................................................................................................191 Transmission Controller........................................................................................191 Self-Diagnostic Display Code Table.........................................................................191 Warning Display Table......................................................................................192 Method of re-enacting fault displayed......................................................................193 Operation of controller when fault is detected.............................................................193 Transmission mode display......................................................................................194 Saving self-diagnostic display to memory.......................................................................194 Saving service code to memory..................................................................................195 TABLE OF SERVICE CODES & ACTION CODES.............................................................................. 0 Table of service codes & action codes related to monitor panel.................................................196 Table of service codes & action codes related to transmission controller.......................................197 Table of service codes & action codes related to suspension controller.........................................200 Table of service codes & action codes related to PMC...........................................................201 METHOD OF USING TABLE..............................................................................................202 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................203 Method of using troubleshooting chart for each troubleshooting fault...........................................203 ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER, MODULE).................................................................205 SETTING ROTARY SWITCH (MODEL & NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER................................206 METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY........................................................207 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM..................................................................211 Troubleshooting Charts.........................................................................................211 Troubleshooting Index......................................................................................211 Points to remember when carrying out troubleshooting of transmission controller system ....................214 Action taken by self-diagnostic device and problems on the truck ..........................................216 Table for transmission controller, transmission related parts .............................................236 A-1 ( u.u ) a) (OFF) Controller self-diagnostic display LED does not light up ...........................238 b001(E. « 0.1) b) Drop in voltage of controller power source is displayed .................................239 b0dA(E. « d.A) c) Drop in voltage of battery direct power source is displayed..............................240 b0db(E. « d.b) d) Drop in voltage of main power source is displayed .......................................241 b002(E. « 0.2) e) Fault in transmission cut relay power source is displayed ...............................242 A-2 b003(E. « 0.3) Fault in neutral safety circuit is displayed ...........................................243 A-3 b005(E. « 0.5) Double engagement for clutch is displayed ..............................................244 A-4 b006(E. « 0.6) Fault in transmission (cut relay) is displayed .........................................245 A-5 b008(E. « 0.8) Fault in rear brake solenoid is displayed ..............................................246 A-6 b009(E. « 0.9) Fault in exhaust brake solenoid is displayed ...........................................247 A-7 b0C4(E. « C.4) a) Short circuit with ground in BCV rear solenoid is displayed..........................248 b0C6(E. « C.6) b) Short circuit in BCV rear solenoid is displayed .........................................248 b0C8(E. « C.8) c) Disconnection in BCV rear solenoid is displayed .........................................250 A-8 b010(E. « 1.0) or b060 (E. « 6.0) .....................................................................251 b011(E. « 1.1) or b061 (E. « 6.1) .........................................................................252 b012(E. « 1.2) or (E. « 6.2) ..............................................................................253 b013(E. « 1.3) or (E. « 6.3)...............................................................................254 A-9 b022(E. « 2.2) or b023 (E. « 2.3) .....................................................................255 b024(E. « 2.4) or b028 (E. « 2.8)..........................................................................256 A-10 b014(E. « 1.4) a) Fault in model selection (wiring harness) is displayed .............................257 b0A1(E. « A.1) b) Fault in model selection (rotary switch) is displayed ...................................258 A-11b007(E. « 0.7) a) Short circuit in shift lever assembly power source is displayed .....................259 b015(E. « 1.5) b) Shift lever position signal input for 2 or more circuit is displayed ....................260 b016(E. « 1.6) c) Shift lever position signal is not inputted .............................................262 A-12 b017(E. « 1.7) Fault in accelerator signal is displayed ..............................................264 A-13b019(E. « 1.9) Fault in transmission oil temperature sensor is displayed ..............................265 A-14b032(E. « 3.2) - b038 (E. « 3.8) .....................................................................266 b042(E. « 4.2) - b048 (E. « 4.8) .........................................................................268 b-1) Checking fill signal..................................................................................268 b042(E. « 4.2) - b043 (E. « 4.3) .........................................................................269 b044(E. « 4.4) - b048 (E. « 4.8) .........................................................................269 A-15b052(E. « 5.2) - b058 (E. « 5.8) .....................................................................270 A-16b071(E. « 7.1) - b078 (E. « 7.8) .....................................................................271 b091(E. « 9.1) - b098 (E. « 9.8) .........................................................................271 A-17b0A2(E. « A.2) a) Fault in torque converter oil temperature sensor is displayed .......................273 b0A3(E. « A.3) b) Fault in fuel level sensor is displayed .................................................274 b0b2(E. « b.2) c) Fault in cooling water temperature sensor is displayed ..................................275 b0b3(E. « b.3) d) Fault in air pressure sensor is displayed ...............................................276 b0b4(E. « b.4) e) Fault in retarder brake oil temperature sensor is displayed .............................277 A-18 b0d1(E. « d.1) a) Transmission filter clogged warning is displayed ...................................278 b0d5(E. « d.5) b) Tilt warning is displayed ...............................................................279 b0d6(E. « d.6) c) Drop in radiator water level warning is displayed .......................................280 b0d7(E. « d.7) d) Battery charge level warning is displayed ...............................................281 b0E5(E. « E.5) e)Steering oil temperature overheat warning is displayed ...................................282 b0F5(E. « F.5) f) Drop in engine oil pressure warning is displayed ........................................283 b0F6(E. « F.6) g) Rear brake oil pressure warning is displayed ............................................284 A-19b0B7(E. « B.7) Fault in engine oil pressure sensor is displayed .......................................285 A-20b0C1(E. « C.1) Fault in connector connection is displayed .............................................286 A-21b0d2(E. « d.2) a) Torque converter oil temperature overheat warning is displayed ......................287 b0d3(E. « d.3) b) Engine water temperature overheat warning is displayed ..................................287 b0E9(E. « E.9) c) Air pressure drop warning is displayed ..................................................287 b0F3(E. « F.3) d) Retarder brake oil temperature overheat warning is displayed ............................287 b0d8(E. « d.8) e) Engine overrun actuated is displayed ....................................................288 b0d9(E. « d.9) f) Engine overshoot actuated is displayed ..................................................288 MONITOR PANEL TROUBLESHOOTING......................................................................................289 TROUBLESHOOTING CHARTS.........................................................................................289 TROUBLESHOOTING INDEX..........................................................................................289 Monitor Panel and Controller Self-diagnostic display.......................................................291 Action taken by self-diagnostic device and problems on truck (monitor panel)...............................292 P-1 Check pattern for wiring harnesses between modules ....................................................296 P-2 Nothing on monitor panel works.........................................................................299 P-3 LH, RH module and fuel gauge do not operate............................................................300 P-4 LH, RH module and fuel gauge do not operate............................................................301 P-5 RH module does not operate.............................................................................302 P-6 LH module does not operate.............................................................................303 P-7 Odometer does not operate..............................................................................304 P-8 Service meter display does not operate correctly.......................................................305 P-9 Central warning lamp does not operate, or monitor panel detects fault code [A002]......................306 P-10 Central warning lamp stays on.........................................................................307 P-11 Alarm buzzer does not operate, or monitor panel detects failure code A003.............................308 P-12 Alarm buzzer continues to sound.......................................................................309 P-13 All data from shift controller (speedometer, tachometer, shift indicator, etc.) are abnormal .........310 P-14 Suspension mode power/economy mode displays are abnormal..............................................311 P-15 Gauge displays are abnormal (nothing is displayed, or display does not change) . .....................312 P-16 Cooling water level drop caution lamp does not operate,...............................................313 P-17 Cooling water level drop caution lamp stays on........................................................314 P-18 Emergency steering pilot lamp does not operate, or monitor panel detects service code [A001]..........315 P-19 Emergency steering pilot lamp stays on................................................................316 P-20 Engine oil pressure drop caution lamp does not operate................................................317 P-21 Engine oil pressure drop caution lamp stays on........................................................318 P-22 Exhaust brake pilot lamp does not operate, or monitor panel detects service code [A001]...............319 P-23 Exhaust brake pilot lamp (optional) stays on .........................................................320 P-24 Charging circuit fault caution lamp does not operate, or monitor panel detects service code [A001.....321 P-25 Charging circuit fault caution lamp stays on..........................................................322 P-26 Transmission filter clogging caution lamp does not operate............................................323 P-27 Transmission filter clogging caution lamp stays on....................................................324 P-28 Brake stroke caution lamp does not operate, or monitor panel detects service code [A001]..............325 P-29 Brake stroke caution lamp stays on....................................................................326 P-30 Preheating switch pilot lamp does not operate, or monitor panel detects service code [A001] ..........327 P-31 Preheating switch pilot lamp stays on.................................................................328 P-32 Tilt warning lamp does not operate, or monitor panel detects service code [A001]......................329 P-33 Tilt warning lamp stays on............................................................................330 P-34 Body FLOAT (except FLOAT) pilot lamp does not operate, or monitor panel detects service code A001.....331 P-35 Body FLOAT (except FLOAT) pilot lamp stays on.........................................................332 P-36 Rear brake pilot lamp does not operate, or monitor panel detects service code [A001]..................333 P-37 Rear brake pilot lamp stays on........................................................................334 P-38 Parking brake pilot lamp does not operate, or monitor panel detects service code [A001]...............335 P-39 Parking brake pilot lamp stays on.....................................................................336 P-40 Maintenance caution lamp does not operate, or monitor panel detects service code [A001]...............337 P-41 Maintenance caution lamp stays on.....................................................................338 P-42 Steering oil temperature caution lamp does not operate, or monitor panel detects service code A001....339 P-43 Steering oil temperature caution lamp stays on........................................................340 P-46 High beam display does not light up...................................................................341 P-47 Turn signal lamp (right) does not light up ...........................................................343 P-48 Turn signal lamp (left) does not light up.............................................................344 P-49 Lamp check switch does not operate....................................................................345 P-50 AISS switch does not operate..........................................................................346 P-51 Exhaust brake switch (optional) does not operate......................................................347 P-52 Mode change switch (1) does not operate...............................................................348 P-53 Mode change switch (2) does not operate...............................................................349 P-54 KPH/MPH speedometer unit selector does not operate....................................................350 P-55 Improper operation of all switch inputs...............................................................351 P-56 Monitor panel detects service codes [A014] or [A019] .................................................352 P-58 Monitor panel detects service code [A011..............................................................353 P-59 Monitor panel detects service code [A012].............................................................353 P-60 Monitor panel detects service code [A000] ...........................................................353 ENGINE ELECTRONIC DIAGNOSTIC SYSTEM................................................................................355 Fault Code Information (T01-001)...............................................................................358 ELECTRICAL SPECIFICATIONS..........................................................................................361 HYDRAULIC & MECHANICAL SYSTEMS TROUBLESHOOTING.....................................................................363 Troubleshooting Index..........................................................................................363 H-1 Truck does not move....................................................................................364 H-2 Truck does not travel smoothly.........................................................................366 H-3 Lock-up clutch cannot be disengaged....................................................................366 H-4 Excessive shock when starting or shifting..............................................................366 H-5 Transmission does not shift up.........................................................................367 H-6 Truck lacks power or speed when moving.................................................................368 H-7 Time lag is excessive when starting to move, or shifting gear .........................................372 H-8 Torque converter oil temperature is high...............................................................374 H-9 Torque converter oil pressure is high..................................................................375 H-10 Front brakes are ineffective, or effective only on one side...........................................376 H-11 Rear brakes are ineffective, or effective on one side only............................................377 H-12 Steering wheel is difficult to turn...................................................................378 H-13 Steering wheel inoperative............................................................................379 H-15 Hoist cylinder lacks lifting force (lifting speed) ...................................................380 H-16 Hoist cylinders do not operate........................................................................382 H-17 Excessive dump body hydraulic drift...................................................................384 H-18 Air pressure does not increase .......................................................................385 SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING (OPTIONAL) SP DIAGNOSTIC FLOWCHART....................................387 SUSPENSION CONTROLLER/SUSPENSION COMPONENTS TROUBLESHOOTING TABLE..............................................388 TRANSMISSION CONTROLLER SYSTEM ELECTRICAL CIRCUIT DIAGRAM......................................................394 SP-1 ALL OFF or Power source fault displayed...................................................................396 SP-2 Faulty pressure sensor (right) displayed..................................................................397 SP-3 Faulty pressure sensor (left) displayed...................................................................398 SP-4 Faulty speed sensor displayed.............................................................................399 SP-5 Fault in steering sensor displayed........................................................................400 SP-6 Defective model selection data displayed..................................................................401 SP-7 Fault in solenoid 1 displayed.............................................................................402 SP-8 Fault in solenoid 2 displayed.............................................................................403 SP-9 Fault in solenoid 3 displayed.............................................................................404 SP-10 Disconnection in network displayed.......................................................................405 SP-11 Defective speed compensation displayed...................................................................406 F - TRANSMISSION.......................................................................................................407 TORQUE CONVERTER OPERATION.........................................................................................410 Main Relief Valve..............................................................................................415 Torque Converter Relief Valve..................................................................................415 Lockup Solenoid Valve..........................................................................................417 Testing Hydraulic Pressure of Torque Converter Valve...........................................................420 Torque Converter Stall Speed...................................................................................422 TRANSMISSION OPERATION.............................................................................................423 ECMV (Electronic Control Modulation Valve).....................................................................427 TRANSMISSION ......................................................................................................438 Removal........................................................................................................438 Installation...................................................................................................440 TRANSMISSION FILTER................................................................................................442 Service........................................................................................................442 TRANSMISSION OIL COOLER............................................................................................443 Removal........................................................................................................443 Installation...................................................................................................443 TRANSMISSION OIL STRAINER..........................................................................................443 Removal........................................................................................................443 Installation...................................................................................................443 TORQUE CONVERTER CONTROL VALVE.....................................................................................444 Removal........................................................................................................444 Installation...................................................................................................444 Disassembly....................................................................................................444 Assembly.......................................................................................................445 DRIVELINES & U-JOINTS..............................................................................................447 Removal........................................................................................................447 Installation...................................................................................................447 Disassembly....................................................................................................447 Assembly.......................................................................................................447 AUTOMATIC SHIFT CONTROL SYSTEM.....................................................................................449 General Information............................................................................................449 Transmission Shift Controller..................................................................................449 Power Mode.................................................................................................449 Braking Mode...............................................................................................449 Lock-Up & Engine Overspeed.................................................................................449 Transmission Speeds Monitoring.............................................................................449 Self Diagnostics...........................................................................................450 Range Selector Positions & Automatic Gear Shifting Ranges......................................................452 Transmission Operation Modes..............................................................................452 Automatic Gear Shifting........................................................................................453 Automatic Shifting Sequence................................................................................453 Safety Functions...........................................................................................455 Transmission Range Selector....................................................................................456 Sensors, Switches..............................................................................................457 Transmission Troubleshooting Procedures........................................................................460 G - WHEELS, SPINDLES & FINAL DRIVE.....................................................................................467 TIRES & RIMS.......................................................................................................469 General Information............................................................................................469 FRONT TIRE & RIM...................................................................................................470 Removal........................................................................................................470 Installation...................................................................................................471 REAR TIRE & RIM....................................................................................................471 Removal........................................................................................................471 Installation of rear wheel assembly............................................................................472 TIRE MATCHING......................................................................................................474 FRONT WHEEL HUB & SPINDLES.........................................................................................475 FRONT WHEEL HUB....................................................................................................475 Removal........................................................................................................475 FRONT WHEEL BEARING & BRAKE DISC REPLACEMENT.......................................................................476 FRONT WHEEL HUB INSTALLATION & BEARING ADJUSTMENT..................................................................477 A-FRAME............................................................................................................478 Removal........................................................................................................478 Installation...................................................................................................478 CENTER TIE ROD PIVOT...............................................................................................479 Removal........................................................................................................479 Inspection.....................................................................................................479 Installation...................................................................................................479 FINAL DRIVE ATTACHMENTS............................................................................................481 Final Drive Lower Link.........................................................................................481 Pin Removal................................................................................................481 Pin Installation...........................................................................................482 Bearing Removal & Inspection...............................................................................482 Bearing Installation.......................................................................................482 Diagonal Panhard Rod...........................................................................................482 Removal....................................................................................................482 Installation...............................................................................................482 Bearing Replacement........................................................................................483 FINAL DRIVE CENTER CASE ASSEMBLY...................................................................................485 Specifications.................................................................................................485 Rear Axle......................................................................................................487 Removal....................................................................................................487 Installation...............................................................................................488 DIFFERENTIAL ASSEMBLY..............................................................................................489 Removal........................................................................................................489 Installation...................................................................................................490 Disassembly....................................................................................................490 Disassembly of Pinion Carrier Assembly.........................................................................491 Differential Gear Unit.........................................................................................492 Disassembly of Differential Gear Unit..........................................................................492 Assembly of Differential.......................................................................................495 Differential Bearing...........................................................................................495 Assembly of Differential Gear Assembly.........................................................................495 Installation of Differential Assembly..........................................................................496 Input Pinion and Carrier Assembly..............................................................................497 Adjusting Tooth Contact, Backlash..............................................................................500 FINAL DRIVE PLANETARIES & WHEEL HUBS...............................................................................503 Final Drive....................................................................................................503 Carrier Assembly...............................................................................................504 Removal....................................................................................................504 Installation...............................................................................................505 Final Drive Carrier............................................................................................505 Disassembly................................................................................................505 Assembly...................................................................................................506 Final Drive Assembly...........................................................................................506 Disassembly................................................................................................506 Assembly...................................................................................................509 H - SUSPENSIONS........................................................................................................511 FRONT SUSPENSION...................................................................................................513 Operation......................................................................................................513 Removal........................................................................................................515 Installation...................................................................................................517 Disassembly....................................................................................................518 Inspection.....................................................................................................519 Assembly.......................................................................................................519 Attenuation Valve Repair.......................................................................................520 REAR SUSPENSION....................................................................................................521 Operation......................................................................................................521 Removal........................................................................................................522 Installation...................................................................................................523 Disassembly....................................................................................................523 Assembly.......................................................................................................524 Spherical Bearing Repair.......................................................................................525 OILING & CHARGING PROCEDURES.......................................................................................527 General........................................................................................................527 Equipment List.................................................................................................527 Front Suspension...............................................................................................527 Front Suspension Oiling....................................................................................528 Front Suspension Nitrogen Charging.........................................................................529 Rear Suspension................................................................................................531 Rear Suspension Oiling.....................................................................................531 Rear Suspension Nitrogen Charging..........................................................................532 J - BRAKE SYSTEM.......................................................................................................535 BRAKE CIRCUIT OPERATION............................................................................................537 Brake Circuit Operation........................................................................................537 Component Description..........................................................................................537 Emergency Relay Valve (RE-6)...................................................................................538 Hand Brake (Retarder)..........................................................................................541 Parking Brake Pilot Valve......................................................................................543 Parking Brake Relay Valve......................................................................................544 Brake Chamber (Front)..........................................................................................545 Brake Chamber (Rear)...........................................................................................545 Slack Adjuster.................................................................................................546 Pressure Switch................................................................................................548 Stop Lamp Switch...............................................................................................548 Parking Brake Switch...........................................................................................549 Automatic Retarder Valve.......................................................................................549 Front Brake Cut-Off Valve......................................................................................550 Brake Cooling Valve (BCV)......................................................................................551 Parking & Emergency Brake Valve................................................................................552 Brake Valve (Treadle)..........................................................................................554 BRAKE CIRCUIT COMPONENT SERVICE....................................................................................559 Service Brake Treadle Valve....................................................................................559 Pressure Converters (Front)....................................................................................562 Pressure Converters (Rear).....................................................................................566 Slack Adjuster.................................................................................................570 BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT..............................................................................573 Checking Front Pad Wear........................................................................................573 Checking Brake Pressure........................................................................................573 Checking Rear Disc Wear........................................................................................574 Brake Bleeding.................................................................................................575 Brake Troubleshooting Charts...................................................................................576 FRONT BRAKES.......................................................................................................579 Brake Pads.....................................................................................................579 Removal....................................................................................................579 Installation...............................................................................................579 Brake Caliper Assembly.........................................................................................579 Removal....................................................................................................579 Installation...............................................................................................580 Disassembly................................................................................................580 Inspection Values......................................................................................580 Assembly...................................................................................................581 REAR BRAKES........................................................................................................583 Removal........................................................................................................583 Installation...................................................................................................584 Disassembly....................................................................................................585 Inspection Values..............................................................................................586 Assembly.......................................................................................................586 PARKING BRAKE......................................................................................................589 Brake Pads.....................................................................................................589 Removal....................................................................................................589 Installation...............................................................................................589 Parking Brake Caliper..........................................................................................589 Removal....................................................................................................589 Installation...............................................................................................590 Disassembly................................................................................................590 Assembly...................................................................................................591 Parking Brake Spring Cylinder..................................................................................591 Removal....................................................................................................591 Installation...............................................................................................591 Disassembly................................................................................................591 Assembly...................................................................................................592 Parking Brake Adjustment.......................................................................................593 Parking Brake Disc.............................................................................................594 Driveshaft Removal.........................................................................................594 Parking Brake Disc Removal.................................................................................594 Inspection Values..........................................................................................595 Parking Brake Disc Installation............................................................................595 Driveshaft Installation....................................................................................595 PARKING BRAKE RELEASE AFTER EMERGENCY APPLY........................................................................595 Release of Parking Brake.......................................................................................595 Release of Emergency Brake.....................................................................................596 K - AIR SYSTEM.........................................................................................................597 AIR SYSTEM OPERATION...............................................................................................599 COMPONENT DESCRIPTION..............................................................................................599 Main Air Tank..................................................................................................599 Safety Valve...................................................................................................599 Air Govenor....................................................................................................599 Air Dryer......................................................................................................600 Air Horn.......................................................................................................602 AIR SYSTEM COMPONENT REPAIR........................................................................................603 Air Compressor Service.........................................................................................603 Air Governor...................................................................................................603 RETARDER VALVE.....................................................................................................605 Removal........................................................................................................605 Installation...................................................................................................605 Disassembly....................................................................................................607 Assembly.......................................................................................................607 L - HYDRAULIC SYSTEM...................................................................................................609 HYDRAULIC SYSTEM OPERATION.........................................................................................611 Component Description..........................................................................................611 HYDRAULIC SYSTEM COMPONENT REPAIR..................................................................................615 Hydraulic Pump.................................................................................................615 Removal....................................................................................................615 Installation...............................................................................................615 Hydraulic Tank.................................................................................................616 Filling Instructions (Hoist Oil Supply)....................................................................616 Filling Instructions (Rear Brake Cooling Oil Supply).......................................................616 Hydraulic Filters..............................................................................................617 Filter Replacement.........................................................................................617 Hydraulic Tank Breather........................................................................................617 Cleaning...................................................................................................617 High Pressure Hydraulic Filters................................................................................618 Removal....................................................................................................618 Installation...............................................................................................618 Replacement................................................................................................619 STEERING CIRCUIT...................................................................................................621 Steering Circuit Operation.....................................................................................621 Demand Valve...................................................................................................622 Steering Control Valve.........................................................................................622 Crossover Relief Valve.........................................................................................623 Operation of Demand & Steering Control Valve...............................................................624 Emergency Steering System......................................................................................632 Flow Switch....................................................................................................633 Relay Timer....................................................................................................633 Emergency Steering System Electrical Schematic.............................................................634 STEERING VALVE ASSEMBLY............................................................................................635 Removal........................................................................................................635 Installation...................................................................................................635 Disassembly....................................................................................................636 Assembly.......................................................................................................641 STEERING CIRCUIT COMPONENT REPAIR..................................................................................649 Emergency Steering Motor Pump Assembly.........................................................................649 Removal....................................................................................................649 Installation...............................................................................................649 Steering Cylinder Assembly.....................................................................................650 Removal....................................................................................................650 Installation...............................................................................................650 Disassembly................................................................................................651 Assembly...................................................................................................653 Demand Valve Assembly..........................................................................................655 Removal....................................................................................................655 Installation...............................................................................................655 Disassembly................................................................................................656 Assembly...................................................................................................656 Relief Valve Assembly..........................................................................................657 Disassembly................................................................................................657 Assembly...................................................................................................657 HOIST CIRCUIT OPERATION & COMPONENT DESCRIPTION....................................................................659 Hoist Circuit Operation........................................................................................659 Hoist Circuit Component Description............................................................................659 HOIST CIRCUIT COMPONENT REPAIR.....................................................................................665 Hoist Valve Assembly...........................................................................................665 Removal....................................................................................................665 Installation...............................................................................................665 Disassembly................................................................................................666 Assembly...................................................................................................666 Hoist Cylinder.................................................................................................668 Removal....................................................................................................668 Installation...............................................................................................669 Disassembly................................................................................................670 Assembly...................................................................................................670 HYDRAULIC SYSTEM CHECKOUT..........................................................................................673 Dump Body Control..............................................................................................673 Adjusting Hoist Lever Linkage..................................................................................674 Adjusting Hoist Limiter........................................................................................675 Testing & Adjusting Hydraulic Pressure in Steering & Hoist Circuit.............................................676 Diagnostic Chart: Hoist System.................................................................................679 Diagnostic Chart: Steering System..............................................................................682 M - OPTIONS & SPECIAL TOOLS............................................................................................685 QUICK FUEL SYSTEM..................................................................................................687 SPECIAL TOOLS......................................................................................................689 AIR CONDITIONING SYSTEM............................................................................................699 PAYLOAD METER II...................................................................................................735 GENERAL INFORMATION............................................................................................737 Haul Cycles................................................................................................737 LIGHTS, SWITCHES, and COMPONENTS...............................................................................738 TIPS FOR OPERATION.............................................................................................739 EXTERNAL DISPLAY LIGHTS........................................................................................739 THEORY OF OPERATION............................................................................................740 Basic Description..........................................................................................740 Inclinometer...............................................................................................740 Linkage Factor.............................................................................................740 Gain Factor................................................................................................741 Brake Lock.................................................................................................741 Sources of Error...........................................................................................741 Typical Data From Service Check Mode.......................................................................741 Calculation Method ........................................................................................742 Example Calculation of Payload.............................................................................742 Calculation of the Calibration Load........................................................................742 Checking the Gain..........................................................................................743 Adjusting the Gain.........................................................................................743 TYPES OF DATA STORED...........................................................................................744 Cycle data.................................................................................................744 Engine ON/OFF Data.........................................................................................745 Fault Codes and Warning Data...............................................................................745 Engine Operation...........................................................................................746 Total Payload and Total Number of Cycles...................................................................746 Other Data.................................................................................................746 OPERATOR FUNCTIONS.............................................................................................747 Using the Operator Load Counter............................................................................747 Viewing the Operator Load Counter..........................................................................747 Clearing the Operator Load Counter.........................................................................747 Dimming the Lights on the Display..........................................................................747 INITIAL SETUP OF PAYLOAD METER.................................................................................748 Switch Settings............................................................................................748 Checking the Operator Check Mode...........................................................................749 Checking the Service Check Mode. ..........................................................................749 Setting "UP:00"........................................................................................749 Setting "PL:00"........................................................................................749 Checking the Gt Setting....................................................................................750 Checking the Inclinometer Settings.........................................................................750 Calibrating a Truck........................................................................................750 DISPLAYS AT START-UP...........................................................................................751 Normal Operation...........................................................................................751 SETUP AND MAINTENANCE..........................................................................................752 Setting the Speed Limit....................................................................................752 Setting the Option Code....................................................................................752 Setting The Machine I.D....................................................................................753 Setting The Operator I.D...................................................................................753 Setting The Time and Date..................................................................................753 DOWNLOAD OF INFORMATION........................................................................................754 DISPLAY OF FAULT CODES.........................................................................................754 Monitoring Input Signals...................................................................................758 Service Check Mode.........................................................................................758 UP FACTOR - PAYLOAD CALCULATION GAIN...........................................................................759 PL MODE -LOAD CALCULATION TIMING...............................................................................759 FINAL GEAR RATIO SELECTION.....................................................................................760 BATTERY REPLACEMENT PROCEDURE..................................................................................761 Replacing the Battery......................................................................................761 After Replacing the Battery................................................................................762 SUSPENSION PRESSURE SENSOR.....................................................................................762 Removal....................................................................................................762 Installation...............................................................................................763 INCLINOMETER...................................................................................................763 Removal....................................................................................................763 Installation...............................................................................................763 Adjustment.................................................................................................763 PAYLOAD METER BACK PANEL CONNECTIONS...........................................................................764 AMP Pin Identification.....................................................................................765 CONNECTIONS....................................................................................................765 PAYLOAD METER II RE-INITIALIZATION PROCEDURE...................................................................766 PAYLOAD CIRCUIT NUMBERS........................................................................................767 TROUBLESHOOTING................................................................................................768 COMMON PROBLEMS............................................................................................768 Suspension Charging....................................................................................768 Symptom Table..........................................................................................769 Missing Body-Up Signal.................................................................................769 Missing Speed Signal...................................................................................770 F-18: Alternator R-Terminal, Oil Pressure Signals......................................................770 Shorted 18v Sensor Power Supply (930E).................................................................770 FAULT TREE DIAGNOSIS.......................................................................................771 Payload Lights Won't Illuminate........................................................................771 Red, Amber or Green Payload Light Does Not Illuminate..................................................772 Cannot Download - PC Communications....................................................................773 PC Communications Configuration........................................................................774 F.CAL: Payload Meter Won't Calibrate...................................................................775 F-20: Sensor Power Fault...............................................................................776 F-21, F-25: Left Front Pressure Sensor.................................................................778 F-22, F-26: Right Front Pressure Sensor................................................................778 F-23, F-27: Left Rear Pressure Sensor..................................................................778 F-24, F-28: Right Rear Pressure Sensor.................................................................778 F-31, F-32: Inclinometer...............................................................................780 Body Up Input..........................................................................................782 Brake Lock Input.......................................................................................783 Speed Signal...........................................................................................784 Adjusting the Speed Sensor.........................................................................784 CONNECTORS AND PRESSURE SENSORS............................................................................786 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM....................................................................789 Menu Functions.............................................................................................792 Using Scope................................................................................................792 Log File Information.......................................................................................792 Connections to Payload Meter II™...........................................................................793 USING SCOPE....................................................................................................794 Monitoring Inputs Using Scope..............................................................................794 Monitoring Suspension Charging Using Scope.................................................................794 Pressure Sensor Dummy Loads................................................................................797 GAIN ADJUSTMENT WORKSHEET......................................................................................798 EXHAUST BRAKE......................................................................................................799 SYSTEM OPERATION...............................................................................................800 Exhaust brake ‘‘ON’’.......................................................................................800 Exhaust brake ‘‘OFF’’......................................................................................800 SYSTEM COMPONENTS..............................................................................................801 Exhaust Brake Pressure Switch..............................................................................801 Exhaust Brake Solenoid Valve...............................................................................801 Exhaust Brake Assembly.....................................................................................802 MAINTENANCE....................................................................................................803 1000 Hour Maintenance......................................................................................803 Gate Adjustment............................................................................................803 TROUBLESHOOTING................................................................................................804 OPERATIONAL CHARACTERISTICS................................................................................804 SYSTEM COMPONENT CHECKS........................................................................................805 Exhaust Brake ON/OFF Switch................................................................................805 Exhaust Brake Pressure Switch..............................................................................805 Exhaust Brake Solenoid.....................................................................................805 N - OPERATOR'S CAB.....................................................................................................807 TRUCK CAB..........................................................................................................809 Removal........................................................................................................809 Installation...................................................................................................809 CAB COMPONENTS.....................................................................................................811 Windshield Wiper...............................................................................................811 Operation..................................................................................................811 Removal....................................................................................................811 Installation...............................................................................................811 Windshield Washer..............................................................................................812 Service....................................................................................................812 Air Cleaner Indicator Gauge....................................................................................813 OPERATOR COMFORT...................................................................................................815 Operator Seat..................................................................................................815 Adjustment Instructions....................................................................................815 Removal....................................................................................................816 Installation...............................................................................................816 Dash Panel.....................................................................................................817 Removal....................................................................................................817 Installation...............................................................................................817 Heater & Air Conditioner Unit..................................................................................817 Removal....................................................................................................817 Installation...............................................................................................817 Disassembly................................................................................................818 Assembly...................................................................................................818 Heater Controls................................................................................................818 Removal....................................................................................................818 Installation...............................................................................................818 OPERATOR CAB & CONTROLS............................................................................................819 Retarder Operation.............................................................................................820 Center Console.................................................................................................821 Engine Electronic Control System...............................................................................824 Hoist Control Lever............................................................................................826 Dump Body Control Linkage......................................................................................828 Steering Column Service........................................................................................829 Instrument Panel...............................................................................................831 Instrument Panel (Upper Half)..................................................................................833 Instrument Panel (Lower Half)..................................................................................836 Heater / Air Conditioner Controls..............................................................................841 P - LUBRICATION & SERVICE..............................................................................................843 LUBRICATION & SERVICE..............................................................................................845 LUBRICATION SPECIFICATIONS CHARTS..................................................................................846 Service Capacities.............................................................................................846 Anti-Freeze Specifications.....................................................................................846 Lubrication Chart..............................................................................................846 10 HOUR (DAILY) LUBRICATION & MAINTENANCE CHECKS...................................................................847 FLUID LEVELS & OTHER CHECKS........................................................................................847 ENGINE.............................................................................................................849 WHEELS AND TIRES...................................................................................................849 Tires..........................................................................................................849 Wheels.........................................................................................................850 OPERATIONAL CHECKS.................................................................................................851 250 HOUR LUBRICATION & MAINTENANCE CHECKS..........................................................................853 INITIAL 250 HOUR SERVICE...........................................................................................853 EVERY 250 HOUR SERVICE.............................................................................................853 500 HOUR LUBRICATION & MAINTENANCE CHECKS..........................................................................855 1000 HOUR LUBRICATION & MAINTENANCE CHECKS.........................................................................856 2000 HOUR LUBRICATION & MAINTENANCE CHECKS.........................................................................857 EVERY 5000 HOUR SERVICE............................................................................................858 HYDRAULIC TANK SERVICE & FILLING INSTRUCTIONS .....................................................................859 Filling Instructions (Hoist Oil Supply)........................................................................859 Filling Instructions (Rear Brake Cooling Oil Supply............................................................859 HYDRAULIC FILTERS..................................................................................................860 Filter Replacement.............................................................................................860 HYDRAULIC TANK BREATHER............................................................................................860 Cleaning.......................................................................................................860 HIGH PRESSURE HYDRAULIC FILTER SERVICE.............................................................................861 Filter Assembly Removal........................................................................................861 Filter Assembly Installation...................................................................................861 Filter Element Replacement.....................................................................................862 TRANSMISSION FILTER SERVICE........................................................................................863 Service........................................................................................................863 PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES.........................................................864 Q - ALPHABETICAL INDEX.................................................................................................865 R - SYSTEM SCHEMATICS..................................................................................................869 HA204 AIR CIRCUIT PIPING...........................................................................................871 HA203 AIR SYSTEM SCHEMATIC.........................................................................................872 HH339 HYDRAULIC SYSTEM SCHEMATIC...................................................................................873 HH340 HYDRAULIC SYSTEM PIPING......................................................................................874 KT-T01 TRANSMISSION CROSS SECTION VIEW.............................................................................875 HE462 ELECTRICAL WIRING SCHEMATIC..................................................................................876 Sheet 1 (1-8)..................................................................................................879 Sheet 2 (9-16).................................................................................................880 Sheet 3 (17-24)................................................................................................881 Sheet 4 (25-32)................................................................................................882 Sheet 5 (33-40)................................................................................................883 Sheet 6 (41-48)................................................................................................884 Sheet 7 (49-56)................................................................................................885 Sheet 8 (57-64)................................................................................................886 Sheet 9 (65-72)................................................................................................887 Sheet 10 (73-80)...............................................................................................888 Sheet 11 (81-88)...............................................................................................889 Sheet 12 (89-96)...............................................................................................890 Sheet 13 (97-104)..............................................................................................891 Sheet 14 (105-112).............................................................................................892 Sheet 15 (113-120).............................................................................................893 Sheet 16 (121-128).............................................................................................894
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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