Komatsu 530M Dump Truck Shop Manual SN A30002-A30038 – PDF DOWNLOAD

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Komatsu 530M Dump Truck Shop Manual

FILE DETAILS:

Komatsu 530M Dump Truck Shop Manual

Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 530M
Serial Number: A30002-A30038
Book Code: CEBM008300
Language: English
Pages: 1043
File Format: Portable Document Format (PDF)

KOMATSU 530M DUMP TRUCK SHOP MANUAL SN A30002-A30038 – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu 530M Dump Truck Shop Manual

FOREWORD:

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 metric and (U.S. standard) units throughout. 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 Introduction section and individual torques are provided in the text in bold face type, such as 723 kg.m (100 ft.lbs.) 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 KOMATSU Haulpak Model designation consists of three numbers and one letter (i.e. 530M). The three numbers represent the basic truck model. The letter ‘‘M’’ designates a Mechanical drive and the letter ‘‘E’’ designates an Electrical propulsion system.
• The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.

TABLE OF CONTENTS:

Komatsu 530M Dump Truck Shop Manual

MAIN MENU............................................................................   0
COVER................................................................................   1
FOREWORD.............................................................................   3
TABLE OF CONTENTS....................................................................   5
GENERAL INFORMATION..................................................................   7
	TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS.....................................   9
	GENERAL SAFETY AND TRUCK OPERATION...............................................  13
	WARNINGS AND CAUTIONS............................................................  29
	CHARTS AND TABLES................................................................  35
	STORAGE PROCEDURES...............................................................  43
STRUCTURES...........................................................................  55
	STRUCTURAL COMPONENTS............................................................  57
		PREPARATION..................................................................  57
		GRILLE, HOOD AND LADDERS.....................................................  58
		DECKS........................................................................  58
			CENTER DECK..............................................................  58
			RIGHT DECK AND COMPONENTS................................................  59
			LEFT DECK AND CAB........................................................  59
	DUMP BODY........................................................................  61
		DUMP BODY....................................................................  61
			REMOVAL..................................................................  61
			INSTALLATION.............................................................  62
		BODY PADS....................................................................  63
		BODY GUIDES..................................................................  64
		BODY-UP RETENTION (SAFETY) CABLE.............................................  65
		ROCK EJECTORS................................................................  65
	FUEL TANK........................................................................  67
		FUEL TANK....................................................................  67
			REMOVAL..................................................................  67
			INSTALLATION.............................................................  68
				CLEANING.............................................................  68
		VENT.........................................................................  68
		FUEL GAUGE SENDER............................................................  68
ENGINE, FUEL, COOLING AND AIR CLEANER................................................  69
	COOLING SYSTEM...................................................................  71
		RADIATOR.....................................................................  71
			REMOVAL..................................................................  72
			INSTALLATION.............................................................  73
			REPAIR...................................................................  74
		HEAT EXCHANGER...............................................................  74
			REMOVAL..................................................................  74
			INSTALLATION.............................................................  75
			REPAIR...................................................................  75
	ENGINE...........................................................................  77
		ENGINE.......................................................................  77
			REMOVAL..................................................................  77
			INSTALLATION.............................................................  80
		DRIVE LINE ADAPTER...........................................................  81
			REMOVAL..................................................................  81
			INSTALLATION.............................................................  82
				DISASSEMBLY..........................................................  83
				ASSEMBLY.............................................................  84
		RECOMMENDED LUBRICANTS.......................................................  84
	AIR FILTRATION SYSTEM............................................................  85
		AIR CLEANER..................................................................  85
			FILTER SERVICE INDICATOR.................................................  85
			MAIN FILTER ELEMENT......................................................  87
			SAFETY FILTER ELEMENT....................................................  87
		AIR INTAKE TROUBLESHOOTING...................................................  88
			MAIN FILTER CLEANING.....................................................  88
			PRECLEANER SECTION CLEANING..............................................  89
ELECTRIC SYSTEM (24VDC, NON-PROPULSION)..............................................  91
	24VDC ELECTRIC SUPPLY SYSTEM (D02017.1)..........................................  93
		ELECTRICAL SYSTEM DESCRIPTION................................................  93
		BATTERY - MAINTENANCE AND SERVICE............................................  93
		BATTERY CHARGING SYSTEM......................................................  94
			GENERAL DESCRIPTION (100 AMP DELCOTRON INTEGRAL CHARGING SYSTEM).........  94
			OPERATING PRINCIPLES.....................................................  95
			ENERGIZING SPEED.........................................................  96
			RATED VOLTAGE............................................................  96
			MAGNETIZING THE ROTOR....................................................  96
			INTEGRAL CHARGIN SYSTEM - TROUBLESHOOTING PROCEDURES.....................  97
			INTEGRAL CHARGING SYSTEM REPAIR..........................................  97
		24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUB SYSTEM (D02017.2)................ 103
			OPERATION................................................................ 103
			STARTERS AND PRELUB SCHEMATIC DIAGRAM.................................... 104
			MAINTENANCE.............................................................. 105
			TROUBLESHOOTING.......................................................... 106
		24 VDC ELECTRIC START SYSTEM (D02017.3)...................................... 109
			OPERATION................................................................ 109
				REMOVAL.............................................................. 109
				INSTALLATION......................................................... 109
			CRANKING MOTOR TROUBLESHOOTING........................................... 110
				DISASSEMBLY.......................................................... 111
				SOLENOID CHECKS...................................................... 114
				ASSEMBLY............................................................. 115
			MAGNETIC SWITCH.......................................................... 116
	24VDC ELECTRICAL SYSTEM COMPONENTS (D03016)...................................... 117
		GENERAL TROUBLESHOOTING...................................................... 117
		CAB MOUNTED COMPONENTS....................................................... 118
			CIRCUIT BREAKER CHART.................................................... 118
			RELAY BOARDS............................................................. 121
			TRUCK INCLINATION SENSORS................................................ 126
			LUBRICATION SYSTEM TIMER................................................. 126
			PMC SYSTEM SWITCHES...................................................... 126
			ACCELERATOR PEDAL........................................................ 127
		24V COMPONENTS (OUTSIDE CAB)................................................. 129
			BATTERY BOX.............................................................. 129
				BATTERY EQUALIZER.................................................... 130
			BODY POSITION SENSOR SWITCHES............................................ 130
				BODY-UP SWITCH ADJUSTMENT............................................ 130
				HOIST LIMIT SWITCH ADJUSTMENT........................................ 130
			SPEED SENSORS............................................................ 132
	SYSTEM CONTROLLERS .............................................................. 133
		POWERTRAIN MANAGEMENT CONTROL SYSTEM (D22001)................................ 135
			SYSTEM DESCRIPTION....................................................... 135
			PMC SYSTEM TROUBLESHOOTING............................................... 137
			EMERGENCY TRUCK OPERATION................................................ 140
			PMC SYSTEM FAULT CODES TABLES............................................ 142
				ELECTRONIC DISPLAY PANEL (EDP OR EDM)................................ 143
				TRANSMISSION CONTROLLER (ATC)........................................ 144
				SUSPENSION CONTROLLER (SSP).......................................... 147
				POWERTRAIN MANAGEMENT CONTROLLER (PMC)............................... 148
				PAYLOAD METER (PLM).................................................. 150
				RETARD AND CONTROL MONITOR (RCM)..................................... 151
				CENSE & CENTRY....................................................... 153
		POWERTRAIN MANAGEMENT CONTROLLER (PMC) - (D23001)............................ 157
			PMC FEATURES............................................................. 157
				LED DISPLAY.......................................................... 157
				DIP SWITCH SETTINGS.................................................. 157
			NORMAL OPERATION - PMC................................................... 158
				COMMUNICATION........................................................ 159
			TROUBLESHOOTING - PMC.................................................... 163
				PMC FAULT CODE TROUBLESHOOTING....................................... 164
				PMC CONTROLLER LOGIC................................................. 172
					PMC FAULT CODE LOGIC DESCRIPTION................................. 173
				PMC WIRING HARNESS CONNECTORS........................................ 204
		TRANSMISSION CONTROLLER (ATC) - (D24001)..................................... 207
			ATC CONTROLLER FEATURES.................................................. 207
				ATC CONTROLLER FEATURES.............................................. 207
					LED DISPLAY...................................................... 207
					ROTARY SWITCH SETTINGS........................................... 207
				SHIFT CONTROL........................................................ 208
			ATC FAULT CODE TROUBLESHOOTING........................................... 213
				ATC FAULT CODE LOGIC DESCRIPTION..................................... 228
			TRANSMISSION CONTROLLER HARNESS CONNECTORS............................... 259
		ELECTRONIC DISPLAY PANEL (EDP) - (D25001).................................... 261
			ELECTRONIC DISPLAY PANEL................................................. 261
				ROTARY SWITCH SETTINGS............................................... 261
				EXTERNAL INDICATOR LAMPS............................................. 264
				DISPLAY SELF-CHECK FUNCTION.......................................... 266
				ACTION CODE DISPLAY.................................................. 267
			ELECTRONIC DISPLAY PANEL TROUBLESHOOTING................................. 268
			EDP WIRING HARNESS CONNECTORS............................................ 287
		RETARD CONTROL AND MONITOR (RCM) - (D26001).................................. 289
			DESCRIPTION.............................................................. 289
			RCM CALIBRATION PROCEDURE................................................ 289
			RCM FAULT CODE TROUBLESHOOTING........................................... 292
		AUTOMATIC SUSPENSION SYSTEM.................................................. 337
			SUSPENSION SYSTEM COMPONENTS............................................. 337
				AUTOMATIC MODE SELECTION CONTROL..................................... 338
				SUSPENSION CONTROLLER FAULT CODE LOGIC DESCRIPTION................... 339
				SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING......................... 342
				SUSPENSION CONTROLLER WIRING HARNESS CONNECTORS...................... 349
		MOM (MESSAGE FOR OPERATION AND MAINTENANCE) - (D30001)....................... 351
			SYSTEM CONFIGURATION..................................................... 351
				SOFTWARE............................................................. 352
				FUNCTION............................................................. 354
			MAINTENANCE INFORMATION (SCREEN HIERARCHY)............................... 354
				DISPLAY ABLE/DISABLE BY MACHINE STATUS............................... 356
					VEHICLE STATE.................................................... 356
				DISPLAY ABLE/DISABLE BY TRUCK MODEL AND OPTIONAL EQUIPMENT STATUS.... 357
			SCREEN DATA.............................................................. 358
			HARDWARE TROUBLESHOOTING AND MAINTENANCE................................. 361
		MOM SCREEN DISPLAYS - (D31001)............................................... 371
			INITIAL MESSAGE SCREENS.................................................. 371
			s1 SERVICE MENU.......................................................... 376
				s2 COMPONENT CHECK MENU.............................................. 376
				s3 MACHINE INFORMATION MENU.......................................... 395
			t1 PARAMETER SET MENU.................................................... 401
		DAD - (DATA ACQUISITION DEVICE) 0 (D32001)................................... 411
			INTRODUCTION............................................................. 411
				HARDWARE HOOKUP...................................................... 411
				SOFTWARE............................................................. 412
			MAINTENANCE INFORMATION (SCREEN HIERARCHY)............................... 413
			SCREEN DATA.............................................................. 418
				REAL TIME DATA....................................................... 418
				FAULT CONDITION DATA................................................. 418
				SNAP-SHOT DATA....................................................... 418
				MACHINE TREND DATA................................................... 419
				MACHINE CHECK........................................................ 420
				MACHINE INFORMATION.................................................. 420
				EVENT RECORDER....................................................... 420
				PARAMETER SET........................................................ 420
		DAD SCREEN DISPLAYS - (D33001)............................................... 421
			PASSWORD INPUT........................................................... 421
			s1 SERVICE MENU.......................................................... 422
				s2 COMPONENT CHECK MENU.............................................. 422
				s3 MACHINE INFORMATION MENU.......................................... 442
			t1 PARAMETER SET MENU.................................................... 447
		REAL TIME DATA TABLES - (D34001)............................................. 455
			ACCESSING REAL TIME DATA SCREENS......................................... 455
TRANSMISSION AND TORQUE CONVERTER.................................................... 465
	TORQUE CONVERTER................................................................. 468
		MAIN RELIEF VALVE............................................................ 471
		TORQUE CONVERTER RELIEF VALVE................................................ 471
		TORQUE CONVERTER REGULATOR VALVE............................................. 472
		LOCK-UP CLUTCH............................................................... 472
		HYDRAULIC PUMP............................................................... 473
	TRANSMISSION..................................................................... 474
		LUBRICATING RELIEF VALVE..................................................... 476
		TRANSMISSION CONTROL VALVE................................................... 477
		ECMV (ELECTRONIC CONTROL MODULATION VALVE)................................... 480
			ECMV REPAIR PROCEDURE.................................................... 484
		TRANSMISSION OIL FILTERS..................................................... 488
		TRANSMISSION REMOVAL......................................................... 489
		TRANSMISSION INSTALLATION.................................................... 490
		PROCEDURE FOR CENTERING THE ENGINE AND TRANSMISSION.......................... 491
	TRANSMISSION OIL COOLER.......................................................... 493
		TRANSMISSION STRAINER........................................................ 493
			REMOVAL.................................................................. 493
			INSTALLATION............................................................. 494
	DRIVE SHAFTS..................................................................... 495
		FRONT DRIVE SHAFT ........................................................... 495
			REMOVAL.................................................................. 495
			INSTALLATION............................................................. 495
		REAR DRIVE SHAFT............................................................. 496
			REMOVAL.................................................................. 496
			INSTALLATION............................................................. 496
	MISCELLANEOUS COMPONENTS......................................................... 497
		TRANSMISSION CONTROLLER...................................................... 498
		TRANSMISSION RANGE SELECTOR.................................................. 500
		SENSORS & SWITCHES........................................................... 501
		TRANSMISSION/TORQUE CONVERTER TROUBLESHOOTING................................ 503
DRIVE AXLE, SPINDLES AND WHEELS...................................................... 507
	TIRES AND RIMS................................................................... 509
		TIRES AND RIMS............................................................... 509
			GENERAL INFORMATION...................................................... 509
		FRONT TIRES AND RIMS......................................................... 510
			REMOVAL.................................................................. 510
			INSTALLATION............................................................. 511
		REAR TIRE AND RIM............................................................ 511
			REMOVAL.................................................................. 511
			INSTALLATION............................................................. 512
		TIRE MATCHING................................................................ 513
		RIM.......................................................................... 514
			TIRE REMOVAL............................................................. 514
			TIRE INSTALLATION........................................................ 514
	FRONT WHEEL HUB AND SPINDLE...................................................... 515
		FRONT WHEEL HUB.............................................................. 515
			REMOVAL.................................................................. 515
			INSTALLATION............................................................. 515
				FRONT WHEEL HUB BEARING ADJUSTMENT................................... 517
		SUSPENSION A-FRAME........................................................... 518
			REMOVAL.................................................................. 518
			INSTALLATION............................................................. 518
		CENTER TIE ROD PIVOT......................................................... 519
			REMOVAL.................................................................. 519
			INSTALLATION............................................................. 519
	FINAL DRIVE ATTACHMENTS.......................................................... 521
		REAR AXLE ATTACHMENT......................................................... 521
			LOWER SIDE LINKS AND CENTER LINK......................................... 521
			PANHARD ROD (DIAGONAL LINK).............................................. 523
	REAR AXLE & FINAL DRIVE ASSEMBLY................................................. 525
		REAR AXLE & FINAL DRIVE ASSEMBLY............................................. 525
			DIFFERENTIAL OPERATION................................................... 525
		REAR AXLE ASSEMBLY........................................................... 526
			REMOVAL.................................................................. 526
			INSTALLATION............................................................. 526
		DIFFERENTIAL ASSEMBLY........................................................ 527
			REMOVAL (FROM AXLE)...................................................... 527
			INSTALLATION (IN AXLE)................................................... 528
				DISASSEMBLY.......................................................... 529
				ASSEMBLY............................................................. 535
					DIFFERENTIAL BEARING............................................. 535
					DIFFERENTIAL GEAR ASSEMBLY....................................... 535
				DIFFERENTIAL ASSEMBLY INSTALLATION (TO CASE)......................... 536
				INPUT PINION AND CARRIER ASSEMBLY.................................... 537
					ADJUSTING TOOTH CONTACT, BACKLASH................................ 540
	FINAL DRIVE PLANETARIES AND WHEEL HUBS........................................... 543
		FINAL DRIVE.................................................................. 543
			CARRIER ASSEMBLY......................................................... 544
				REMOVAL.............................................................. 544
				INSTALLATION......................................................... 545
			FINAL DRIVE CARRIER...................................................... 545
				FINAL DRIVE CARRIER.................................................. 545
					DISASSEMBLY...................................................... 545
					ASSEMBLY......................................................... 546
			FINAL DRIVE ASSEMBLY..................................................... 546
				FINAL DRIVE ASSEMBLY................................................. 546
					DISASSEMBLY...................................................... 546
					ASSEMBLY......................................................... 549
SUSPENSIONS.......................................................................... 551
	FRONT SUSPENSION................................................................. 553
		OPERATION.................................................................... 554
		SUSPENSION OPERATION (STANDARD EQUIPMENT).................................... 554
		3-MODE SUSPENSION (OPTIONAL EQUIPMENT)....................................... 555
			3-MODE SUSPENSION SYSTEM COMPONENTS...................................... 556
				AUTOMATIC SUSPENSION CONTROLLER (ASC)................................ 556
				MANIFOLD VALVE....................................................... 556
				ACTUATOR............................................................. 557
				STEERING SENSOR...................................................... 557
			SUSPENSION REMOVAL....................................................... 558
			SUSPENSION INSTALLATION.................................................. 559
				DISASSEMBLY.......................................................... 560
				INSPECTION........................................................... 560
				ASSEMBLY............................................................. 560
			DAMPING VALVE REPAIR..................................................... 562
				DAMPING VALVE (FIXED RATE)........................................... 562
				DAMPING VALVE/ACTUATOR (3-MODE DAMPING RATE)......................... 563
	REAR SUSPENSION.................................................................. 565
		OPERATION.................................................................... 566
			REMOVAL.................................................................. 567
			INSTALLATION............................................................. 567
				DISASSEMBLY.......................................................... 568
				ASSEMBLY............................................................. 569
			SPHERICAL BEARING REPAIR................................................. 570
	OILING AND CHARGING PROCEDURES................................................... 571
		GENERAL...................................................................... 571
		EQUIPMENT LIST............................................................... 571
		FRONT SUSPENSION............................................................. 571
			FRONT SUSPENSION OILING.................................................. 572
			FRONT SUSPENSION NITROGEN CHARGING....................................... 573
		REAR SUSPENSION.............................................................. 575
			REAR SUSPENSION OILING................................................... 575
			REAR SUSPENSION NITROGEN CHARGING........................................ 576
			ADJUSTING LENGTH OF FRONT AND REAR CYLINDERS............................. 577
BRAKE CIRCUIT........................................................................ 579
	BRAKE CIRCUIT.................................................................... 581
		SERVICE BRAKE CIRCUIT........................................................ 581
			SECONDARY BRAKING AND AUTOMATIC APPLY.................................... 583
			PARKING BRAKE CIRCUIT.................................................... 583
			BRAKE LOCK CIRCUIT....................................................... 584
			AUXILIARY CIRCUIT........................................................ 584
			RETARDING CIRCUIT........................................................ 584
			WARNING CIRCUIT.......................................................... 584
			BRAKE SYSTEM ELECTICAL COMPONENTS........................................ 585
	BRAKE CIRCUIT COMPONENT SERVICE.................................................. 589
		BRAKE VALVE.................................................................. 589
			REMOVAL.................................................................. 590
			INSTALLATION............................................................. 590
				DISASSEMBLY.......................................................... 591
				CLEANING AND INSPECTION.............................................. 592
				ASSEMBLY............................................................. 594
			DIFFERENTIAL PRESSURE SWITCH............................................. 597
			VALVE BENCH TEST AND ADJUSTMENT.......................................... 598
				DIFFERENTIAL PRESSURE SWITCH ADJUSTMENT.............................. 599
				PROXIMITY SWITCH INSTALLATION AND ADJUSTMENT......................... 601
		RELAY VALVES................................................................. 603
			RELAY VALVE.............................................................. 603
				DISASSEMBLY.......................................................... 604
				CLEANING AND INSPECTION.............................................. 605
				ASSEMBLY............................................................. 605
			VALVE TEST AND ADJUSTMENT................................................ 606
		HYDRAULIC BRAKE ACCUMULATORS................................................. 608
			BRAKE ACCUMULATOR BLEED DOWN PROCEDURE................................... 608
			BRAKE ACCUMULATOR CHARGING PROCEDURE..................................... 609
			BRAKE ACCUMULATOR REBUILD................................................ 610
			BRAKE COOLING VALVE (BCV)................................................ 613
		RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)............................. 614
			REMOVAL.................................................................. 614
			INSTALLATION............................................................. 614
			DISASSEMBLY AND ADJUSTMENT............................................... 615
			POTENTIONMETER CHECK..................................................... 615
			ASSEMBLY................................................................. 615
	BRAKE CIRCUIT CHECKOUT PROCEDURE................................................. 617
		BRAKE CIRCUIT CHECKOUT PROCEDURE............................................. 617
			EQUIPMENT REQUIRED....................................................... 620
			INITIAL SYSTEM SET-UP.................................................... 620
		BRAKE SYSTEM CHECKOUT........................................................ 622
		FAILURE MODES CHECK-OUT...................................................... 623
	BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING.................................... 629
	HYDRAULIC BRAKE SYSTEM CHECKOUT PROCEDURE DATA SHEET............................. 633
	FRONT WET DISC BRAKES............................................................ 643
		DESCRIPTION.................................................................. 643
			REMOVAL.................................................................. 644
			INSTALLATION............................................................. 645
		DISC BRAKE MAINTENANCE....................................................... 645
			BRAKE DISC WEAR INDICATOR................................................ 645
			WEAR INDICATOR SENSOR.................................................... 647
			BRAKE BLEEDING PROCEDURE................................................. 647
	REAR WET DISC BRAKES............................................................. 649
		DESCRIPTION.................................................................. 649
			DESCRIPTION.............................................................. 649
		DISC BRAKE MAINTENANCE....................................................... 650
			BRAKE DISC WEAR INDICATOR................................................ 650
			WEAR INDICATOR SENSOR.................................................... 651
		DISC BRAKE REBUILD PROCEDURE................................................. 652
			REMOVAL AND INSTALLATION................................................. 652
				REMOVAL.............................................................. 652
				INSTALLATION......................................................... 653
			BRAKE ASSEMBLY REBUILD (FRONT AND REAR).................................. 654
				DISASSEMBLY.......................................................... 654
				CLEANING AND INSPECTION.............................................. 655
				ASSEMBLY............................................................. 656
			FLOATING RING SEAL ASSEMBLY/INSTALLATION................................. 657
	PARKING BRAKE.................................................................... 661
		DESCRIPTION.................................................................. 661
			REMOVAL.................................................................. 662
			INSTALLATION............................................................. 662
		PARKING BRAKE SPRING CYLINDER REPLACEMENT.................................... 664
		PARKING BRAKE CHECK-OUT PROCEDURE............................................ 664
HYDRAULIC SYSTEM..................................................................... 667
	HYDRAULIC SYSTEM................................................................. 669
		HYDRAULIC SYSTEM DESCRIPTION................................................. 669
	HYDRAULIC COMPONENT REPAIR....................................................... 673
		HYDRAULIC TANK............................................................... 673
			FILLING INSTRUCTIONS..................................................... 673
			HYDRAULIC TANK SERVICE................................................... 673
				REMOVAL.............................................................. 674
				INSTALLATION......................................................... 674
			STRAINERS AND DIFFUSERS.................................................. 675
			HYDRAULIC TANK BREATHER.................................................. 676
		HYDRAULIC SYSTEM FLUSHING PROCEDURE.......................................... 677
		HYDRAULIC PUMPS.............................................................. 678
			HYDRAULIC PUMPS.......................................................... 678
				REMOVAL.............................................................. 678
				INSTALLATION......................................................... 678
			PUMP REBUILD (HOIST AND BRAKE COOLING PUMPS)............................. 679
		TROUBLESHOOTING GUIDE........................................................ 687
	STEERING CIRCUIT................................................................. 689
		STEERING CIRCUIT OPERATION................................................... 689
		COMPONENT DESCRIPTION........................................................ 689
			STEERING CONTROL VALVE................................................... 689
			BLEED DOWN MANIFOLD VALVE................................................ 690
			BLEED DOWN SOLENOID...................................................... 690
			ACCUMULATORS............................................................. 690
			HIGH PRESSURE FILTER..................................................... 690
			WARNING DEVICES.......................................................... 690
			FLOW AMPLIFIER........................................................... 690
				OPERATION............................................................ 692
			STEERING/BRAKE PUMP...................................................... 700
	STEERING CONTROL VALVE........................................................... 703
		STEERING CONTROL VALVE....................................................... 703
			REMOVAL.................................................................. 703
			INSTALLATION............................................................. 703
		REBUILD PROCEDURE............................................................ 704
			DISASSEMBLY.............................................................. 704
			CLEANING AND INSPECTION.................................................. 705
			ASSEMBLY................................................................. 707
	STEERING CIRCUIT COMPONENT REPAIR................................................ 711
		BLEEDDOWN MANIFOLD VALVE..................................................... 711
		FLOW AMPLIFIER VALVE......................................................... 713
		STEERING ACCUMULATORS........................................................ 717
		STEERING ACCUMULATOR CHARGING PROCEDURE...................................... 720
		STEERING CYLINDER............................................................ 721
		STEERING/BRAKE PUMP.......................................................... 724
			REMOVAL AND INSTALLATION................................................. 724
				REMOVAL.............................................................. 724
				INSTALLATION......................................................... 725
			PUMP REBUILD............................................................. 726
				DISASSEMBLY.......................................................... 726
				ASSEMBLY............................................................. 731
		TROUBLESHOOTING CHART........................................................ 734
	HOIST CIRCUIT.................................................................... 737
		HOIST CIRCUIT OPERATION...................................................... 737
		COMPONENT DESCRIPTION........................................................ 738
	HOIST CIRCUIT COMPONENT REPAIR................................................... 751
		HOIST VALVE.................................................................. 751
		HOIST PILOT VALVE............................................................ 758
		HOIST CYLINDERS.............................................................. 761
	HYDRAULIC SYSTEM FILTERS......................................................... 769
		HIGH PRESSURE FILTER (STEERING CIRCUIT)...................................... 769
		LOW PRESSURE FILTERS (BRAKE, HOIST & TRANSMISSION)........................... 770
	HYDRAULIC CHECK-OUT PROCEDURE.................................................... 773
		STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE............................ 773
			STEERING COMPONENTS LEAKAGE TEST......................................... 776
		CHECKING HOIST SYSTEM PRESSURES.............................................. 777
			HOIST RELIEF VALVE ADJUSTMENT............................................ 777
			POWER DOWN RELIEF VALVE ADJUSTMENT....................................... 778
OPTIONS AND SPECIAL TOOLS............................................................ 779
	FIRE CONTROL SYSTEMS............................................................. 781
		ANSUL FIRE CONTROL - "CHECKFIRE" ELECTRIC SYSTEM (M02003).................... 781
		ANSUL FIRE CONTROL SYSTEM (MANUAL) (M02004).................................. 791
			OPERATION................................................................ 791
			INSPECTION AND MAINTENANCE............................................... 791
			RECHARGING PROCEDURES.................................................... 792
	WIGGINS QUICK FILL FUEL SYSTEM (M05002).......................................... 793
		FUEL RECEIVER................................................................ 793
		TANK BREATHER VALVE.......................................................... 794
		LEFT SIDE FILL............................................................... 795
	FAN DRIVE CLUTCH................................................................. 797
	SPECIAL TOOLS (M08013)........................................................... 835
	HEATER/AIR CONDITIONING SYSTEM - 134a REFRIGERANT (M09010)....................... 837
		ENVIRONMENTAL IMPACT......................................................... 837
		OPERATOR CAB AIR CONDITIONING................................................ 838
		PRINCIPLES OF REFRIGERATION.................................................. 838
		MAJOR SYSTEM COMPONENTS...................................................... 840
		SYSTEM SERVICING............................................................. 843
		EVACUATING THE SYSTEM........................................................ 854
		SYSTEM TROUBLESHOOTING....................................................... 855
	PAYLOAD METER II - ON - BOARD WEIGHING SYSTEM (M20007) .......................... 865
		TABLE OF CONTENTS............................................................ 865
		PAYLOAD METER II - GENERAL INFORMATION (M20007).............................. 868
			HAUL CYCLES.............................................................. 868
		LIGHTS, SWITCHES, AND COMPONENTS............................................. 869
		TIPS FOR OPERATION........................................................... 870
		EXTERNAL DISPLAY LIGHTS...................................................... 870
		THEORY OF OPERATION.......................................................... 871
			BASIC DESCRIPTION........................................................ 871
			INCLINOMETER............................................................. 871
			LINKAGE FACTOR........................................................... 871
			GAIN FACTOR.............................................................. 872
			BRAKE LOCK............................................................... 872
			SOURCES OF ERROR......................................................... 872
			TYPICAL DATA FROM SERVICE CHECK MODE..................................... 872
			EXAMPLE CALCULATION OF PAYLOAD........................................... 873
			VIEWING PAYLOAD CALCULATION INPUTS....................................... 873
		TYPES OF DATA STORED......................................................... 875
			CYCLE DATA............................................................... 875
			ENGINE ON/OFF DATA....................................................... 876
			FAULT CODES AND WARNING DATA............................................. 876
			ENGINE OPERATION......................................................... 877
			TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES................................. 877
			OTHER DATA............................................................... 877
		OPERATOR FUNCTIONS........................................................... 878
			USING THE OPERATOR LOAD COUNTER.......................................... 878
			VIEWING THE OPERATOR LOAD COUNTER........................................ 878
			CLEARING THE OPERATOR LOAD COUNTER....................................... 878
			DIMMING THE LIGHTS ON THE DISPLAY........................................ 878
		INITIAL SETUP OF PAYLOAD METER............................................... 879
			SWITCH SETTINGS.......................................................... 879
			CHECKING THE OPERATOR CHECK MODE......................................... 880
			CHECKING THE SERVICE CHECK MODE.......................................... 880
				SETTING "UP:00"...................................................... 880
				SETTING "PL:00"...................................................... 880
			CHECKING THE Gt SETTING.................................................. 881
			CHECKING THE INCLINOMETER SETTINGS....................................... 881
			CALIBRATING A TRUCK...................................................... 881
		DISPLAY AT START-UP.......................................................... 882
		SETUP AND MAINTENANCE........................................................ 883
			SETTING THE SPEED LIMIT.................................................. 883
			SETTING THE OPTION CODE.................................................. 883
			SETTING THE MACHINE I.D. CODE............................................ 884
			SETTING THE OPERATOR I.D. CODE........................................... 884
			SETTING THE TIME AND DATE................................................ 884
		DOWNLOAD OF INFORMATION...................................................... 885
		DISPLAY OF FAULT CODES....................................................... 885
		CHARTS OF ERROR CODES AND OTHER INFORMATION.................................. 887
		MONITORING INPUT SIGNALS..................................................... 889
		SERVICE CHECK MODE........................................................... 889
		UP FACTOR - PAYLOAD CALCULATION GAIN......................................... 890
		PL MODE - LOAD CALCULATION TIMING............................................ 890
		FINAL GEAR RATIO SELECTION................................................... 891
		BATTERY REPLACEMENT PROCEDURE................................................ 892
			REPLACING THE BATTERY ................................................... 892
			AFTER REPLACING THE BATTERY ............................................. 893
		SUSPENSION PRESSURE SENSOR................................................... 893
			REMOVAL.................................................................. 893
			INSTALLATION............................................................. 894
		INCLINOMETER................................................................. 894
			REMOVAL.................................................................. 894
			INSTALLATION............................................................. 894
			ADJUSTMENT............................................................... 894
		PAYLOAD METER BACK PANEL..................................................... 895
		CONNECTIONS (AMP PIN IDENTIFICATION)......................................... 896
		PAYLOAD CIRCUIT NUMBERS...................................................... 897
		PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE................................ 898
		TROUBLESHOOTING SECTION...................................................... 899
		COMMON PROBLEMS.............................................................. 899
			SUSPENSION CHARGING...................................................... 899
			SYMPTOM TABLE............................................................ 900
			MISSING BODY-UP SIGNAL................................................... 900
			MISSING SPEED SIGNAL..................................................... 901
			F-18: ALTERNATOR R-TERMINAL, OIL PRESSURE SIGNALS........................ 901
			SHORTED 18V SENSOR POWER SUPPLY (930E)................................... 901
		FAULT TREE DIAGNOSIS......................................................... 902
			PAYLOAD LIGHTS DON'T ILLUMINATE.......................................... 902
			RED, AMBER, OR GREEN PAYLOAD LIGHTS DON'T ILLUMINATE..................... 903
			CONNOT DOWNLOAD - PC COMMUNICATIONS...................................... 904
			PC COMMUNICATIONS CONFIGURATION.......................................... 905
			F.CAL: PAYLOAD METER WON'T CALIBRATE..................................... 906
			F-20: SENSOR POWER FAULT................................................. 907
			F-21 THRU F-28 PRESSURE SENSOR FAULTS.................................... 909
			F-31, F-32: INCLINOMETER................................................. 911
			BODY UP INPUT............................................................ 913
			BRAKE LOCK INPUT......................................................... 914
			SPEED SIGNAL............................................................. 915
		CONNECTORS AND PRESSURE SENSORS.............................................. 917
		REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM.................................. 920
			DATA DEFINITIONS AND COMMENTS............................................ 921
			TRUCK STATUS AND INPUTS.................................................. 922
			MENU FUNCTIONS........................................................... 923
			USING SCOPE.............................................................. 923
			LOG FILE INFORMATION..................................................... 923
			CONNECTIONS TO PAYLOAD METER II™......................................... 924
		USING SCOPE.................................................................. 925
			MONITORING INPUTS USING SCOPE............................................ 925
			MONITORING SUSPENSION CHARGING USING SCOPE............................... 925
			PRESSURE SENSOR DUMMY LOADS.............................................. 928
		GAIN ADJUSTMENT WORKSHEET.................................................... 929
	CAB RADIO (M27001)............................................................... 931
OPERATOR'S CAB....................................................................... 933
	TRUCK CAB........................................................................ 935
		DESCRIPTION.................................................................. 935
			DESCRIPTION.............................................................. 935
		PREPARATION FOR REMOVAL...................................................... 936
			REMOVAL.................................................................. 936
			INSTALLATION............................................................. 937
		CAB DOOR..................................................................... 938
			REMOVAL.................................................................. 938
			INSTALLATION............................................................. 938
			DOOR ADJUSTMENT.......................................................... 938
			DOOR JAM BOLT ADJUSTMENT................................................. 938
		GLASS REPLACEMENT............................................................ 941
	CAB COMPONENTS................................................................... 949
		WINDSHIELD WIPER............................................................. 949
		WINDSHIELD WASHER............................................................ 950
		HEATER/AIR CONDITIONER....................................................... 951
			OPERATION................................................................ 951
		HEATER COMPONENTS............................................................ 951
			CIRCUIT BREAKERS......................................................... 951
			HEATER COIL.............................................................. 952
			FAN MOTOR AND SPEED CONTROL.............................................. 952
			ACTUATORS................................................................ 952
			FILTER................................................................... 952
		HEATER/AIR CONDITIONER ASSEMBLY (EXPLODED PARTS ILLUSTRATION)................ 953
	OPERATOR CAB AND CONTROLS........................................................ 955
		OPERATOR CAB AND CONTROLS.................................................... 955
			STEERING WHEEL AND CONTROLS.............................................. 956
			RETARDER CONTROL LEVER................................................... 957
			SERVICE BRAKE PEDAL...................................................... 957
			THROTTLE PEDAL........................................................... 957
			INSTRUMENT PANEL......................................................... 957
			HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS.......................... 958
			RETARDING CAPACITY CHART................................................. 959
			RADIO SPEAKERS........................................................... 960
			"MOM" DISPLAY SCREEN..................................................... 960
			WARNING ALARM BUZZER..................................................... 960
			CAB RADIO................................................................ 960
			AIR CLEANER VACUUM GAUGES................................................ 960
			PAYLOAD METER............................................................ 960
			WINDSHIELD WIPERS........................................................ 960
		CENTER CONSOLE STRUCTURE..................................................... 961
			TRANSMISSION RANGE SELECTOR.............................................. 962
			CONTROL SWITCHES......................................................... 962
			SHIFT LIMITER SWITCH..................................................... 962
			F-1 START SWITCH ........................................................ 962
			HOIST CONTROL LEVER...................................................... 962
			PARKING BRAKE SWITCH..................................................... 963
			L.H. WINDOW CONTROL SWITCH............................................... 963
			R.H. WINDOW CONTROL SWITCH............................................... 963
			ASH TRAY................................................................. 963
			LIGHTER.................................................................. 963
			PASSENGER SEAT W/SAFETY BELT............................................. 963
		OPERATOR SEAT................................................................ 964
	INSTRUMENT PANEL AND INDICATORS.................................................. 965
		INSTRUMENT PANEL AND INDICATORS.............................................. 965
			KEYSWITCH................................................................ 966
			EMERGENCY BRAKE SWITCH................................................... 966
			R.H. CONTROL/INDICATOR PANEL (POD)....................................... 967
			CENTER DISPLAY PANEL..................................................... 967
			L.H. CONTROL/INDICATOR PANEL (POD)....................................... 967
			LADDER LIGHT SWITCH...................................................... 967
			HEADLIGHT SWITCH......................................................... 967
			BACKUP/DECK LIGHTS SWITCH................................................ 967
			ELECTRONIC DISPLAY SWITCHES.............................................. 967
		R.H. CONTROL/INDICATOR PANEL (FIGURE 5-2).................................... 968
			DISCUSSION OF ITEMS 1-10, FIGURE 5-2..................................... 968
		CENTER DISPLAY PANEL......................................................... 970
			DISCUSSION OF ITEMS 1-29, FIGURE 5-3..................................... 970
		L.H. CONTROL/INDICATOR PANEL (POD) (FIGURE 5-4).............................. 973
			DISCUSSION OF ITEMS 1-21, FIGURE 5-4..................................... 973
		REAR OF OPERATOR CAB......................................................... 976
		CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS................................ 978
			DETERMINING "FAULT" CODES................................................ 978
			EXITING THE DIAGNOSTICS MODE............................................. 979
LUBRICATION AND SERVICE.............................................................. 981
	LUBRICATION AND SERVICE (P02022)................................................. 983
		SERVICE CAPACITIES........................................................... 983
		ANTI-FREEZE SPECIFICATIONS................................................... 983
		TRANSMISSION OIL LEVEL CHECK................................................. 983
		LUBRICATION CHART (OIL & GREASE SPECIFICATIONS).............................. 984
		10 HOURS..................................................................... 985
		250 HOURS.................................................................... 987
		500 HOURS.................................................................... 989
		1000 HOURS................................................................... 990
		2000 HOURS................................................................... 991
		5000 HOURS................................................................... 992
		HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS)................................ 993
		STEERING CIRCUIT FILTER...................................................... 994
		HYDRAULIC TANK BREATHER...................................................... 995
		PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES................... 996
	LINCOLN AUTOMATIC LUBRICATION SYSTEM (P03013).................................... 997
		LINCOLN AUTOMATIC LUBRICATION SYSTEM......................................... 997
			SYSTEM COMPONENTS........................................................ 997
			SYSTEM OPERATION.........................................................1000
			SYSTEM PRIMING...........................................................1001
			SYSTEM CHECKOUT..........................................................1001
			PRESSURE REDUCER ADJUSTMENT..............................................1001
			24 VDC SOLID STATE TIMER CHECK...........................................1002
			24 VDC SOLID STATE TIMER ADJUSTMENT......................................1002
			INJECTORS & ADJUSTMENT...................................................1003
			PUMP CYCLE ("FLASHER") TIMER, INSTALLATION & ADJUSTMENT..................1005
		TROUBLESHOOTING CHART........................................................1007
		RESERVOIR FILL PROCEDURE.....................................................1009
		PREVENTIVE MAINTENANCE PROCEDURES............................................1010
ALPHABETICAL INDEX...................................................................1011
SYSTEM SCHEMATICS....................................................................1015
	HYDRAULIC SYSTEM SCHEMATIC.......................................................1017
	HYDRAULIC BRAKE SCHEMATIC........................................................1018
	ELECTRICAL SCHEMATIC.............................................................1019

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