Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu 830E Dump Truck Operation & Maintenance Manual A30733-A30815 – PDF DOWNLOAD
Original price was: $52.95.$30.95Current price is: $30.95.
Komatsu 830E Dump Truck Operation & Maintenance Manual
SERIAL NUMBERS A30733 – A30815
Book Code: CEAM015001
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu 830E Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu 830E Dump Truck Operation & Maintenance Manual
Language : English
Pages : 947
Downloadable : Yes
File Type : PDF
Size: 29.5 MB
Book Code: CEAM015001
DESCRIPTION:
Komatsu 830E Dump Truck Operation & Maintenance Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, 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 æ10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E).
- The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
TABLE OF CONTENTS:
Komatsu 830E Dump Truck Operation & Maintenance Manual
MAIN MENU...................................................................................... 0 COVER.......................................................................................... 1 FOREWORD....................................................................................... 5 TABLE OF CONTENTS.............................................................................. 7 SECTION A...................................................................................... 9 SECTION A2 - MAJOR COMPONENTS & SPECIFICATIONS............................................. 11 SECTION A3 - GENERAL SAFETY AND OPERATING INSTRUCTIONS - INDEX............................. 15 GENERAL SAFETY......................................................................... 17 Safety Rules....................................................................... 17 Truck Safety Features.............................................................. 17 Clothing And Personal Items........................................................ 17 Unauthorized Modification.......................................................... 17 Leaving The Operator’s Seat........................................................ 17 Mounting And Dismounting........................................................... 17 Fire Extinguishers And First Aid Kits.............................................. 18 Precautions For High Temperature Fluids............................................ 18 Asbestos Dust Hazard Prevention.................................................... 18 Fire Prevention For Fuel And Oil................................................... 18 ROPS Precautions................................................................... 19 Preventing Injury From Work Equipment.............................................. 19 Precautions For Optional Attachments............................................... 19 Precautions When Starting The Machine.............................................. 19 PRECAUTIONS FOR TRUCK OPERATION.................................................... 20 Safety Is Thinking Ahead....................................................... 20 Safety At The Worksite......................................................... 20 Fire Prevention................................................................ 20 Preparing For Operation........................................................ 20 Ventilation For Enclosed Areas................................................. 20 Mirrors, Windows, And Lights................................................... 20 In The Operator’s Cab - Before Starting The Engine............................. 21 OPERATING THE MACHINE.............................................................. 21 Starting The Engine............................................................ 21 Truck Operation - General...................................................... 21 Traveling In The Truck......................................................... 22 Precautions When Traveling In Reverse.......................................... 22 Traveling On Slopes............................................................ 22 Ensuring Good Visibility....................................................... 23 Operating On Snow.............................................................. 23 Avoid Damage To The Dump Body.................................................. 23 Driving Near High Voltage Cables............................................... 23 When Loading The Truck......................................................... 23 When Dumping................................................................... 23 Working On Loose Ground........................................................ 23 Parking The Machine............................................................ 24 TOWING............................................................................. 24 WORKING NEAR BATTERIES............................................................. 24 Jump Starting With Booster Cables.............................................. 24 PRECAUTIONS FOR MAINTENANCE............................................................ 25 BEFORE PERFORMING MAINTENANCE...................................................... 25 Stopping The Engine Before Service............................................. 25 Warning Tag.................................................................... 25 Proper Tools................................................................... 25 Securing The Dump Body......................................................... 25 DURING MAINTENANCE................................................................. 26 Personnel...................................................................... 26 Attachments.................................................................... 26 Working Under The Machine...................................................... 26 Keeping The Machine Clean...................................................... 26 Rules To Follow When Adding Fuel Or Oil........................................ 26 Radiator Coolant Level......................................................... 26 Use Of Lighting................................................................ 26 Precautions With The Battery................................................... 27 Handling High Pressure Hoses................................................... 27 Precautions With High Pressure Oil............................................. 27 Maintenance Near High Temperatures And High Pressures.......................... 27 Rotating Fan And Belts......................................................... 27 Waste Materials................................................................ 27 TIRES.............................................................................. 28 Handling Tires................................................................. 28 Storing Tires After Removal.................................................... 28 ADDITIONAL JOB SITE RULES.............................................................. 29 WHEN REPAIRS ARE NECESSARY............................................................. 30 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK........................................ 31 Preliminary Procedures before Welding or Performing Maintenance.................... 31 Normal Engine Shutdown Procedure................................................... 31 Engine Shutdown Procedure before Welding or Performing Maintenance................. 31 TRUCK OPERATION........................................................................ 34 PREPARING FOR OPERATION............................................................ 34 Safety Is Thinking Ahead....................................................... 34 WALK AROUND INSPECTION............................................................. 34 ENGINE START-UP SAFETY PRACTICES................................................... 38 AFTER STARTING THE ENGINE.......................................................... 39 Additional Guidelines.......................................................... 39 MACHINE OPERATION SAFETY PRECAUTIONS............................................... 39 MACHINE OPERATION ON THE HAUL ROAD................................................. 40 DYNAMIC RETARDING OPERATION........................................................ 41 Dynamic Retarder Control Lever................................................. 41 Dynamic Retarder/Service Brake Pedal........................................... 41 STARTING ON A GRADE WITH A LOADED TRUCK............................................ 42 PASSING............................................................................ 42 LOADING............................................................................ 42 DUMPING............................................................................ 42 Raising The Dump Body.......................................................... 42 Lowering The Dump Body......................................................... 43 TOWING............................................................................. 44 SAFE PARKING PROCEDURES............................................................ 45 NORMAL ENGINE SHUTDOWN PROCEDURE................................................... 45 DELAYED ENGINE SHUTDOWN PROCEDURE.................................................. 45 SUDDEN LOSS OF ENGINE POWER........................................................ 46 SECTION A4 - WARNINGS AND CAUTIONS......................................................... 47 SECTION A5 - STANDARD CHARTS AND TABLES.................................................... 55 SECTION A7 - STORAGE AND IDLE MACHINE PREPARATION - INDEX.................................. 61 STORAGE AND IDLE MACHINE PREPARATION................................................... 63 Short Term Idle Periods............................................................ 63 PREPARATION FOR STORAGE............................................................ 64 REMOVAL FROM STORAGE............................................................... 65 RECONDITIONING AN IDLE VEHICLE..................................................... 67 ENGINE OPERATION................................................................... 70 After The Engine Has Started................................................... 71 ENGINE STORAGE..................................................................... 72 Preparing Engine For Storage................................................... 72 Temporary Storage (30 Days Or Less)............................................ 72 Extended Storage (more Than 30 Days)........................................... 72 RESTORING AN ENGINE AFTER EXTENDED STORAGE......................................... 74 ELECTRIC DRIVE TRUCKS.............................................................. 75 Storage Instructions and Procedures............................................ 75 Placing Equipment Into Storage................................................. 75 Storing A Truck That Is Operational............................................ 75 Storing A Truck That Is Not Operational........................................ 76 Storing A Major Component...................................................... 76 Periodic Inspections........................................................... 77 Placing Equipment Into Service After Storage................................... 77 When A Truck Is Operational.................................................... 77 When A Truck Is Not Operational................................................ 77 For The First Hour............................................................. 78 SECTION B - STRUCTURES - INDEX................................................................. 79 SECTION B2 - STRUCTURAL COMPONENTS - INDEX................................................. 81 STRUCTURAL COMPONENTS.................................................................. 83 Preparation........................................................................ 83 GRILLE, HOOD AND LADDER............................................................ 84 Removal........................................................................ 84 Installation................................................................... 84 DECKS.............................................................................. 85 RIGHT DECK AND COMPONENTS.......................................................... 85 Removal........................................................................ 85 Installation................................................................... 86 LEFT DECK.......................................................................... 86 Removal........................................................................ 86 Installation................................................................... 86 CENTER DECK........................................................................ 86 SECTION B3 - DUMP BODY - INDEX............................................................. 87 DUMP BODY.............................................................................. 89 Removal............................................................................ 89 Installation....................................................................... 90 BODY PADS.......................................................................... 91 Adjustment..................................................................... 91 BODY GUIDE......................................................................... 92 HOIST LIMIT SWITCH................................................................. 92 BODY UP SWITCH..................................................................... 92 BODY-UP RETENTION CABLE............................................................ 92 ROCK EJECTORS...................................................................... 93 Rock Ejectors (Type I)......................................................... 93 Inspection..................................................................... 93 Rock Ejectors (Type II)........................................................ 94 Inspection..................................................................... 94 SECTION B4 - FUEL TANK - INDEX............................................................. 95 FUEL TANK.............................................................................. 97 Removal............................................................................ 98 Installation....................................................................... 98 Repair............................................................................. 98 Cleaning........................................................................... 98 FUEL GAUGE SENDER.................................................................. 99 Removal........................................................................ 99 Installation................................................................... 99 LOW FUEL SWITCH.................................................................... 99 WIGGINS QUICK FILL FUEL SYSTEM.........................................................100 FUEL RECEIVER......................................................................100 TANK BREATHER VALVE................................................................100 Removal........................................................................100 Installation...................................................................100 Disassembly....................................................................100 Assembly.......................................................................100 LEFT SIDE FILL.....................................................................101 FUEL - WATER SEPARATOR.............................................................102 Installation...................................................................102 Filter Service.................................................................103 Backflushing Procedure.........................................................103 Filter Element Replacement.....................................................103 SECTION C - ENGINE - INDEX.....................................................................105 SECTION C2 - POWER MODULE - INDEX..........................................................107 Preparation............................................................................109 Preparation for Removal................................................................110 Power Module Removal...................................................................113 Power Module Installation..............................................................115 Power Module Hookup....................................................................115 Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul)....117 SECTION C3 - COOLING SYSTEM - INDEX........................................................119 COOLING SYSTEM.........................................................................121 COOLING SYSTEM DESCRIPTION.........................................................121 Coolant Flow...................................................................121 RADIATOR...........................................................................122 Removal........................................................................122 RADIATOR REPAIR....................................................................124 Internal Inspection............................................................124 External Cleaning..............................................................124 Disassembly....................................................................125 Cleaning and Inspection........................................................126 Assembly.......................................................................126 Pressure Testing...............................................................127 Additional Service Information.................................................127 Installation...................................................................128 RADIATOR FILL PROCEDURE............................................................128 Radiator Pressure Regulator Valve..............................................129 COOLING SYSTEM TROUBLESHOOTING.....................................................129 SECTION C4 - POWERTRAIN - INDEX............................................................131 POWER TRAIN............................................................................133 ALTERNATOR REMOVAL PROCEDURE.......................................................133 Removal (MTU/DDC 4000 Engine)..................................................133 ENGINE/ALTERNATOR MATING...........................................................135 General Instructions...........................................................135 MEASURING PROCEDURE................................................................135 Joining Alternator and MTU/DDC Engine..........................................137 ENGINE.............................................................................138 Removal........................................................................138 Service........................................................................138 Installation...................................................................138 SECTION C5 - AIR CLEANERS - INDEX.........................................................139 AIR CLEANERS...........................................................................141 AIR CLEANERS.......................................................................141 Operation......................................................................141 General Service Information....................................................141 FILTER ELEMENT REPLACEMENT.........................................................142 Main Filter Element Cleaning...................................................143 Precleaner Section.............................................................144 Cleaning Precleaner Tubes......................................................144 AIR INTAKE TROUBLESHOOTING.........................................................145 SECTION C7 - FAN CLUTCH - INDEX............................................................147 FAN CLUTCH.............................................................................149 REMOVAL & INSTALLATION TOOLING.....................................................149 FAN CLUTCH - DISASSEMBLY...........................................................152 CLEANING AND INSPECTION............................................................162 ASSEMBLY - FAN CLUTCH..............................................................166 TEST PROCEDURE.....................................................................180 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX...................................181 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX ......................................183 24VDC ELECTRIC SUPPLY SYSTEM...........................................................185 ELECTRICAL SYSTEM DESCRIPTION......................................................185 BATTERIES..........................................................................185 Maintenance and Service........................................................185 Troubleshooting................................................................185 BATTERY SUPPLY SYSTEM..............................................................187 24VDC Battery Charging Alternator..............................................187 Battery Box....................................................................187 Battery Control Box............................................................187 System Battery Starter Disconnect Relay........................................187 Battery Disconnect Switches....................................................188 24VDC Auxiliary Battery Connectors.............................................188 Battery Equalizer..............................................................189 Troubleshooting................................................................189 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX....................................191 24 VDC ELECTRICAL SYSTEM COMPONENTS....................................................193 PASSENGER SEAT BASE COMPARTMENT....................................................193 TRUCK SHUTDOWN PROCEDURE...........................................................193 COMPONENTS.........................................................................193 Tail Light Resistor Diode Assemblies...........................................193 5 Minute Idle Timer Components.................................................193 Inclinometer...................................................................195 Brake Warning Buzzer (BWB).....................................................195 Alarm Indicating Device (AID) System...........................................195 ELECTRICAL INTERFACE CABINET.......................................................198 Lubrication System Timer.......................................................198 Barometric Pressure Transducer.................................................198 Special Interface Module.......................................................198 Power Distribution Terminals...................................................198 Truck Control Interface Panel..................................................198 Control Power Relay............................................................198 Circuit Breaker Panel..........................................................198 Diode Board - DB1..............................................................200 Diode Testing..................................................................200 RELAY BOARDS.......................................................................201 Relay Boards - RB1, RB2, RB3, RB4, RB5.........................................201 Service........................................................................201 Relay Board Identification.....................................................202 Relay Board Functions..........................................................203 Relay Board 6 (RB6)............................................................204 BODY-UP SWITCH.....................................................................205 Operation......................................................................205 Adjustment.....................................................................205 Service........................................................................205 HOIST LIMIT SWITCH.................................................................206 Operation......................................................................206 Adjustment.....................................................................206 Service........................................................................206 SECTION D5 - DDEC ELECTRONIC ENGINE CONTROL - INDEX........................................209 DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE..........................211 COMPONENT DESCRIPTION..............................................................212 Electronic Control Module......................................................212 Electronic Unit Nozzles........................................................214 System Sensors and Operator Inputs.............................................214 ENGINE PROTECTION SYSTEM...........................................................215 DIAGNOSTICS........................................................................216 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX..........................................217 BATTERY CHARGING ALTERNATOR............................................................219 ELECTRICAL SYSTEM DESCRIPTION......................................................219 BATTERY............................................................................219 Maintenance and Service........................................................219 Troubleshooting................................................................219 BATTERY CHARGING SYSTEM (Niehoff)..................................................221 General Description............................................................221 TROUBLESHOOTING PROCEDURES (On-Truck)..............................................221 Equipment Required:............................................................221 Preliminary Checks.............................................................222 Test Setup.....................................................................222 Test Procedure.................................................................222 Regulator Bypass Test..........................................................223 ON VEHICLE TROUBLESHOOTING GUIDE.......................................................225 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage.........225 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:...................................225 CHARGE VOLT AND AMP VALUES.........................................................226 DEFINITIONS........................................................................226 ADVANCED SYSTEM TROUBLESHOOTING........................................................227 Static Test - Engine OFF, Key ON, Battery Switch ON................................227 Go To Alternator...................................................................227 Go To Regulator (If Required)......................................................228 Go To Regulator Connector On The Alternator........................................228 ALTERNATOR OVERHAUL....................................................................229 ALTERNATOR DIMENSIONS..............................................................229 ALTERNATOR SPECIFICATIONS..........................................................230 SERVICE PARTS......................................................................231 ON-VEHICLE TEST....................................................................233 Equipment:.....................................................................233 Preliminary Checks:............................................................233 Test Set-up....................................................................233 Test Procedure.................................................................233 ON-VEHICLE TEST....................................................................234 Bypass Test:...................................................................234 BENCH TEST.........................................................................235 STATIC TESTS.......................................................................236 Regulator Tests................................................................236 Control Box Tests..............................................................237 ALTERNATOR DISASSEMBLY.............................................................239 ASSEMBLY- ALTERNATOR...............................................................244 BF4822 STATOR SERVICE TOOL INSTRUCTIONS................................................253 Stator Removal And Replacement.....................................................253 Stator Installation................................................................254 SECTION E - ELECTRICAL PROPULSION SYSTEM - INDEX...............................................257 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX...............................259 ELECTRICAL PROPULSION SYSTEM COMPONENTS................................................261 GENERAL SYSTEM DESCRIPTION.........................................................261 SYSTEM COMPONENTS..................................................................263 Auxiliary Blower System........................................................263 Propulsion System Controller (PSC).............................................263 TRUCK CONTROL INTERFACE PANEL (TCI)................................................264 Diagnostic Information Display.................................................265 DID PANEL EVENT CODES..............................................................265 PSC SOFTWARE FUNCTIONS.............................................................290 Input Processing...............................................................290 STATE MANAGEMENT...................................................................290 State Machine..................................................................290 Transitions Between States.....................................................291 DC Link State..................................................................293 Powering the Link..............................................................293 De-Powering the Link...........................................................293 Control Functions..............................................................293 Engine Control.................................................................293 ALTERNATOR FIELD CONTROL...........................................................294 Desired Three-Phase Voltage....................................................294 Desired DC Link Voltage........................................................294 Self-load......................................................................294 Propel Torque Control..........................................................295 Retard Torque Control..........................................................295 Wheel Slide Control............................................................295 Resistor Grid Control..........................................................296 Chopper Voltage Control........................................................296 AUXILIARY BLOWER CONTROL...........................................................296 EVENT PROCESSING...................................................................296 Event Detection................................................................296 Power On Tests.................................................................296 Initiated Tests................................................................297 Periodic Tests.................................................................297 EVENT RESTRICTIONS.................................................................297 EVENT LOGGING AND STORAGE..........................................................297 Event History Buffer...........................................................298 Data Packs.....................................................................298 To Record and Save a Data Pack to a Floppy Disk................................298 Event Reset....................................................................299 SERIAL DATA COMMUNICATIONS.........................................................300 PSC - TCI Communications processing............................................300 PSC - PTU Communications Processing............................................300 Inverter Communications Processing.............................................300 OUTPUT PROCESSING..................................................................301 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS...........................................301 Fast Start.....................................................................301 Engine Shutdown/Engine Not Running.............................................301 Limp Home Mode.................................................................301 Entering/Exiting Limp Home Mode................................................301 PROPULSION SYSTEM COMPONENT ABBREVIATIONS..........................................302 ELECTRONIC ACCELERATOR AND RETARD PEDALS...........................................312 Removal........................................................................312 Installation...................................................................312 Disassembly....................................................................312 Assembly.......................................................................312 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE - INDEX.........................313 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE..........................................315 AC DRIVE SYSTEM MAINTENANCE........................................................315 TRUCK SHUTDOWN PROCEDURES..........................................................315 NORMAL TRUCK SHUTDOWN PROCEDURE....................................................316 SHUTDOWN AFTER SYSTEM FAILURE......................................................317 SYSTEM CHECKOUT....................................................................318 Battery and Control Checks of System WITH Battery Power OFF....................318 Battery and Control Circuit Checks of System With Battery Power ON.............321 Checks with Key Switch OFF.....................................................322 CPU Battery Checks.............................................................324 MEMORY BACKUP BATTERY REPLACEMENT..................................................324 TCI PROGRAMMING....................................................................325 PSC PROGRAMMING....................................................................325 INVERTER PROGRAMMING...............................................................326 TCI CHECKOUT.......................................................................326 Modular Mining Communication Port..............................................327 TCI Input Checks...............................................................328 TCI Digital Output Tests.......................................................330 TCI Digital Input Tests........................................................332 PSC Checkout Procedure.........................................................334 PSC Digital Input Checks.......................................................338 Miscellaneous Checks...........................................................339 A3PV Panel.....................................................................339 LINKV Panel....................................................................339 Thermistor Checks..............................................................339 17FM384 Panel Check............................................................339 Pedal Percentages and Meter Calibration........................................340 Meter Calibration Procedure....................................................340 Reprogram With Serial Numbers and Pedal Percentages............................342 LOAD TESTING.......................................................................344 Preload Checks.................................................................344 ADDITIONAL TRUCK CHECKS............................................................346 On-Board Load Testing..........................................................348 Preparation....................................................................348 Initiate Loadbox Test..........................................................351 Manual Offset HP Output Adjustment.............................................353 TROUBLESHOOTING........................................................................355 PVM Optimum Load Curve Handshaking Troubleshooting.................................355 MISCELLANEOUS COMPONENT REPAIR.....................................................356 Troubleshooting Phase Modules and Chopper Modules..............................356 Phase Module Removal and Snubber Resistor Replacement..........................356 Snubber Resistor Installation..................................................357 Phase Module Installation......................................................357 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING...................................358 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING...................................361 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING...........................................362 IGBT TROUBLESHOOTING...............................................................363 SECTION G - REAR AXLE, SPINDLE, AND WHEELS - INDEX.............................................365 SECTION G2 - TIRES AND RIMS - INDEX........................................................367 TIRES AND RIMS.........................................................................369 WHEEL STUD MAINTENANCE.............................................................370 FRONT TIRES AND RIMS...............................................................371 Removal........................................................................371 Installation...................................................................372 REAR TIRES AND RIMS................................................................373 Removal........................................................................373 Installation...................................................................374 RIM................................................................................375 Tire Removal...................................................................375 Tire Installation..............................................................376 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX...........................................379 FRONT WHEEL HUB AND SPINDLE............................................................381 WHEEL HUB AND SPINDLE ASSEMBLY.....................................................381 Preparation....................................................................381 Removal........................................................................381 Installation - Wheel Hub and Spindle Assembly..................................384 Disassembly - Wheel Hub and Spindle Assembly...................................385 Cleaning and Inspection - Wheel Hub and Spindle Assembly.......................385 Assembly - Wheel Hub and Spindle Assembly......................................387 Wheel Bearing Adjustment:......................................................387 Brake Installation.............................................................388 Seal Assembly Gap Check........................................................389 STEERING CYLINDERS AND TIE ROD.....................................................390 Spherical Bearing Wear Limits..................................................390 Removal - Steering Cylinder and Tie Rod........................................391 Installation - Steering Cylinder and Tie Rod...................................392 Bearing Replacement............................................................392 TOE-IN ADJUSTMENT..................................................................393 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX..........................................395 REAR AXLE HOUSING ATTACHMENT...........................................................397 PIVOT PIN..........................................................................397 Removal........................................................................397 Installation...................................................................397 PIVOT EYE BEARING..................................................................398 Disassembly....................................................................398 Assembly.......................................................................398 PIVOT EYE REPAIR...................................................................399 Removal........................................................................399 Disassembly....................................................................399 Assembly.......................................................................399 Installation...................................................................399 ANTI-SWAY BAR......................................................................400 Removal........................................................................400 Installation...................................................................400 Disassembly....................................................................400 Cleaning and Inspection........................................................400 Assembly.......................................................................400 SECTION G5 - REAR AXLE HOUSING - INDEX.....................................................401 REAR AXLE HOUSING......................................................................403 REAR AXLE HOUSING..................................................................403 Preparation....................................................................403 Removal........................................................................403 Cleaning and Inspection - Rear Axle Housing....................................405 Installation - Rear Axle Housing...............................................405 WHEEL MOTOR........................................................................406 Preparation....................................................................406 Removal........................................................................406 Cleaning and Inspection - Wheel Motor..........................................407 Installation - Wheel Motor.....................................................408 WHEEL MOTOR GEAR OIL...............................................................411 Filtering Requirements.........................................................411 Particle Size Analysis.........................................................411 Flushing.......................................................................411 Oil Sample Analysis............................................................412 ELEMENT SPECIFICATION CHARTS.......................................................413 SECTION H - HYDRAIR II SUSPENSIONS - INDEX.....................................................417 SECTION H2 - FRONT SUSPENSIONS - INDEX.....................................................419 FRONT SUSPENSION.......................................................................421 Removal............................................................................421 Installation - Front Suspension....................................................422 "Turn-Of-The-Nut" Tightening Procedure.............................................425 MINOR REPAIRS (LOWER BEARING & SEALS)..............................................426 Removal - Bearing Retainer.....................................................426 Installation - Bearing Retainer................................................426 MAJOR SUSPENSION REBUILD...........................................................428 Disassembly....................................................................428 Assembly.......................................................................428 SECTION H3 - REAR SUSPENSIONS - INDEX......................................................431 REAR SUSPENSIONS.......................................................................433 Removal............................................................................433 Installation - Rear Suspension.....................................................435 Disassembly - Rear Suspension......................................................436 Cleaning and Inspection - Rear Suspension..........................................436 Assembly - Rear Suspension.........................................................436 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX..............................439 SUSPENSION OILING AND CHARGING PROCEDURE...............................................441 GENERAL............................................................................441 EQUIPMENT LIST.....................................................................441 Hydrair® Charging Kit..........................................................441 Installation of Charging Kit...................................................441 Removal of Charging Kit........................................................442 Support Blocks For Oiling And Charging Dimensions..............................442 FRONT SUSPENSION...................................................................443 Front Suspension Oiling........................................................443 Front Suspension Nitrogen Charging.............................................444 REAR SUSPENSION....................................................................445 Rear Suspension Oiling.........................................................445 Rear Suspension Nitrogen Charging..............................................446 OIL AND NITROGEN SPECIFICATIONS CHART..................................................448 SECTION J - BRAKE CIRCUIT - INDEX..............................................................449 SECTION J2 - BRAKE CIRCUIT - INDEX.........................................................451 BRAKE CIRCUIT..........................................................................453 SERVICE BRAKE CIRCUIT..............................................................453 SECONDARY BRAKING AND AUTOMATIC APPLY..............................................455 PARKING BRAKE CIRCUIT..............................................................455 BRAKE LOCK CIRCUIT.................................................................456 WARNING CIRCUIT....................................................................456 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX.......................................459 BRAKE CIRCUIT COMPONENT SERVICE........................................................461 BRAKE VALVE........................................................................461 Rebuild Criteria...............................................................461 Removal - Brake Valve..........................................................462 Installation - Brake Valve.....................................................462 Disassembly - Brake Valve......................................................463 Cleaning and Inspection - Brake Valve..........................................466 Assembly - Actuator Base Threaded Inserts......................................466 Assembly - Boot and Cap........................................................466 Installation - Valve Body Seal.................................................466 Installation - Regulator Sleeve O-Ring.........................................467 Installation - Actuator Plunger O-ring.........................................467 Assembly - Brake Valve.........................................................467 DIFFERENTIAL PRESSURE SWITCH.......................................................469 Disassembly....................................................................469 Cleaning and Inspection........................................................469 Assembly.......................................................................469 VALVE BENCH TEST AND ADJUSTMENT....................................................470 Test Set Up Procedure..........................................................471 Adjustment - Brake Valve Output Pressure.......................................471 Adjustment - Differential Pressure Switch......................................471 Final Test and Adjustment......................................................472 Installation - Brake Pedal Actuator Assembly to Brake Valve....................473 Installation - Retard Pedal To Brake Pedal.....................................473 DUAL RELAY VALVE...................................................................475 Removal........................................................................475 Installation...................................................................475 Disassembly - Dual Relay Valve.................................................477 Cleaning and Inspection - Dual Relay Valve.....................................477 Assembly - Dual Relay Valve....................................................477 DIFFERENTIAL PRESSURE SWITCH.......................................................478 Disassembly....................................................................478 Cleaning and Inspection........................................................478 Assembly.......................................................................478 VALVE TEST AND ADJUSTMENT..........................................................479 Test Set Up Procedure..........................................................480 Adjustment - Brake Valve Output Pressure.......................................480 Adjustment - Differential Pressure Switch......................................481 BRAKE MANIFOLD.....................................................................482 Removal........................................................................482 Installation...................................................................483 Disassembly....................................................................483 Cleaning and Inspection........................................................483 Assembly.......................................................................483 HYDRAULIC BRAKE ACCUMULATORS.......................................................484 Brake Accumulator Bleed Down Procedure.........................................484 ACCUMULATORS - HYDRAULIC COMPONENT CABINET.........................................484 Removal........................................................................484 Installation...................................................................484 Disassembly....................................................................484 Cleaning and Inspection........................................................486 Assembly.......................................................................486 BLADDER ACCUMULATOR CHARGING PROCEDURE.............................................488 Temperature During Precharge...................................................489 Precharge Maintenance..........................................................489 Accumulator Storage Procedures.................................................490 Bladder Storage Procedures.....................................................491 ACCUMULATORS - FRAME MOUNTED.......................................................491 Removal........................................................................491 Installation...................................................................491 Disassembly....................................................................493 Cleaning and Inspection........................................................493 Assembly - Accumulator.........................................................494 Accumulator Testing............................................................494 ACCUMULATOR CHARGING PROCEDURE.....................................................495 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)...................................496 Removal - Retarder Control Lever...............................................496 Installation - Retarder Control Lever..........................................496 Disassembly and Adjustment - Retarder Control Lever............................497 Potentiometer Check - Retarder Control Lever...................................497 Assembly - Retarder Control Lever..............................................497 SECTION J4 - BRAKE CIRCUIT CHECKOUT PROCEDURE - INDEX......................................499 BRAKE CIRCUIT CHECK-OUT PROCEDURE......................................................501 EQUIPMENT REQUIRED.................................................................503 INITIAL SYSTEM SET-UP..............................................................504 BRAKE SYSTEM CHECKOUT..............................................................505 Failure Modes Check-Out........................................................506 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING..........................................509 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET..................................513 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX...............................................515 WET DISC BRAKE ASSEMBLY................................................................517 OPERATION..........................................................................517 MAINTENANCE........................................................................518 Brake Disc Wear Indicator......................................................518 Removal/Installation - Wet Disc Brake Assembly.................................518 BRAKE REBUILD......................................................................520 Disassembly....................................................................520 Cleaning and Inspection........................................................523 Assembly.......................................................................524 Floating Ring Seal Assembly/Installation.......................................527 WET DISC BRAKE BLEEDING PROCEDURE..................................................530 SECTION J7 - PARKING BRAKE - INDEX.........................................................531 PARKING BRAKE..........................................................................533 OPERATION..........................................................................533 MAINTENANCE........................................................................534 Inspection - Parking Brake.....................................................534 Removal - Parking Brake........................................................534 Installation - Parking Brake...................................................535 Disassembly - Parking Brake....................................................536 Cleaning and Inspection - Parking Brake........................................536 Assembly - Parking Brake.......................................................536 PARKING BRAKE BLEEDING PROCEDURE...................................................538 SECTION L - HYDRAULIC SYSTEM - INDEX...........................................................539 SECTION L2 - HYDRAULIC SYSTEM - INDEX......................................................541 HYDRAULIC SYSTEM.......................................................................543 Hoist Circuit Operation............................................................544 Steering Circuit Operation.........................................................546 Disc Brake Cooling System..........................................................548 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX.....................................551 HYDRAULIC SYSTEM COMPONENT REPAIR......................................................553 HOIST PUMP.........................................................................553 Removal........................................................................553 Installation...................................................................555 Disassembly....................................................................556 Inspection Of Parts............................................................560 Assembly.......................................................................560 TROUBLESHOOTING GUIDE..................................................................565 HYDRAULIC TANK.....................................................................566 Filling Instructions...........................................................566 Removal........................................................................566 Installation...................................................................567 HYDRAULIC TANK STRAINERS...........................................................567 Removal........................................................................567 Inspect and Clean..............................................................567 Installation...................................................................567 Hydraulic Tank Breathers.......................................................568 SECTION L4 - STEERING CIRCUIT - INDEX......................................................569 STEERING CIRCUIT.......................................................................571 STEERING CIRCUIT OPERATION.........................................................571 COMPONENT DESCRIPTION..............................................................572 Steering Control Valve.........................................................572 Bleeddown Manifold Valve.......................................................573 Bleeddown Solenoids............................................................573 Accumulators...................................................................574 Low Precharge Warning Switch...................................................574 High Pressure Filter...........................................................574 Flow Amplifier.................................................................574 FLOW AMPLIFIER SYSTEM OPERATION....................................................576 No Steer.......................................................................576 Steering Left..................................................................578 Steering Right.................................................................580 No Steer, External Shock Load..................................................582 STEERING PUMP......................................................................584 Operation......................................................................584 High Altitude Operation........................................................584 PRINCIPLE OF OPERATION.............................................................586 Steering Pump..................................................................587 SECTION L5 - STEERING CONTROL UNIT - INDEX.................................................589 STEERING CONTROL UNIT..................................................................591 Removal............................................................................591 Installation.......................................................................591 STEERING CONTROL UNIT REBUILD......................................................592 Disassembly....................................................................592 Cleaning and Inspection - Steering Control Unit................................593 Assembly - Steering Control Unit...............................................595 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX.....................................599 STEERING CIRCUIT COMPONENT REPAIR......................................................601 BLEEDDOWN MANIFOLD VALVE...........................................................601 Removal........................................................................601 Installation...................................................................601 ACCUMULATORS.......................................................................602 Removal........................................................................602 Installation...................................................................602 Disassembly....................................................................603 Cleaning and Inspection........................................................603 Assembly.......................................................................604 TESTING........................................................................604 STEERING ACCUMULATOR CHARGING PROCEDURE............................................605 FLOW AMPLIFIER.................................................................606 Removal........................................................................606 Installation...................................................................606 FLOW AMPLIFIER REBUILD.........................................................606 Disassembly....................................................................608 Assembly.......................................................................609 STEERING CYLINDERS.................................................................610 Disassembly....................................................................611 Piston Seal & Bearing Installation.............................................611 Cylinder Assembly..............................................................611 Test...........................................................................611 STEERING AND BRAKE PUMP............................................................612 Removal........................................................................612 Installation...................................................................612 Disassembly........................................................................614 Control Piston Group...........................................................614 Valve Plate Group..............................................................614 Rotating Group.................................................................617 Swashblock Group...............................................................617 Driveshaft Group...............................................................617 Inspection.........................................................................617 Control Piston Group...........................................................617 Valve Plate Group..............................................................617 Rotating Group.................................................................617 Swashblock Group...............................................................619 Driveshaft Group...............................................................620 Compensator Block and Unloader Module..........................................620 Stroke Adjuster Assembly.......................................................620 Assembly...........................................................................620 Swashblock Group...............................................................620 Driveshaft Group...............................................................621 Rotating Group.................................................................621 Control Piston Group...........................................................621 Valve Plate Group..............................................................622 TROUBLESHOOTING CHART..................................................................623 SECTION L7 - HOIST CIRCUIT - INDEX.........................................................629 HOIST CIRCUIT..........................................................................631 HOIST CIRCUIT OPERATION............................................................631 COMPONENT DESCRIPTION..............................................................632 Hydraulic Tank.................................................................632 Hydraulic Pump.................................................................632 High Pressure Filters..........................................................632 Hoist Valve....................................................................632 Inlet Sections.................................................................632 Spool Sections.................................................................633 Work Ports (Rear) Spool Section................................................633 Tank Ports (Front) Spool Section...............................................633 Hoist Pilot Valve..............................................................633 Hoist Up Limit Solenoid........................................................634 Pilot Operated Check Valve.....................................................634 Snubber Valve..................................................................634 Counterbalance Valve...........................................................634 HOIST CIRCUIT OPERATION............................................................634 POWER UP OPERATION (Figure 7-5)................................................636 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX........................................645 HOIST CIRCUIT COMPONENT REPAIR.........................................................647 HOIST VALVE........................................................................647 Removal........................................................................647 Installation...................................................................648 O-Ring Replacement.............................................................648 INLET SECTION..................................................................649 Disassembly....................................................................649 Cleaning and Inspection........................................................650 Assembly.......................................................................650 REAR SPOOL SECTION (Work Ports)................................................650 Disassembly....................................................................650 Cleaning and Inspection........................................................652 Assembly.......................................................................652 FRONT SPOOL SECTION (Tank Ports)...............................................653 Disassembly....................................................................653 Cleaning and Inspection........................................................653 Assembly.......................................................................653 HOIST PILOT VALVE..................................................................655 Removal........................................................................655 Installation...................................................................655 Disassembly....................................................................656 Cleaning and Inspection........................................................657 Assembly.......................................................................657 HOIST - UP LIMIT SOLENOID VALVE................................................658 HOIST CYLINDERS....................................................................658 Removal........................................................................658 Installation...................................................................659 Disassembly....................................................................661 Cleaning and Inspection........................................................662 ASSEMBLY OF QUILL AND CYLINDER.................................................663 Quill Installation.............................................................663 Installation Of Check Balls And Plugs In Quill.................................664 Assembly of Cylinder...........................................................665 DISABLED TRUCK DUMPING PROCEDURE...................................................666 HOOKUP.........................................................................666 DUMPING PROCEDURE..............................................................666 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX..............................................667 HYDRAULIC SYSTEM FILTERS...............................................................669 HOIST CIRCUIT FILTER...............................................................669 Filter Element Replacement.....................................................669 Removal - Hoist Circuit Filter.................................................670 Installation - Hoist Circuit Filter............................................670 Indicator Switch - Hoist Circuit Filter........................................670 STEERING CIRCUIT FILTER............................................................671 Filter Element Replacement.....................................................671 Removal - Steering Circuit Filter..............................................672 Installation - Steering Circuit Filter.........................................672 Indicator Switch - Steering Circuit Filter.....................................672 INDICATOR SWITCH...................................................................672 Test Procedure.................................................................672 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX........................................675 HYDRAULIC CHECK-OUT PROCEDURE..........................................................677 GENERAL INFORMATION................................................................677 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE..................................677 Equipment Requirements.........................................................678 Pump Pressure Control Adjustments..............................................678 Steering Control Valve and Flow Amplifier Leakage Test.........................679 Bleeddown Manifold Leakage Test................................................679 Steering / Brake Pump Stroke Adjustment........................................680 Shock And Suction Valves.......................................................681 Equipment Requirements.........................................................681 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES......................682 Equipment Requirements.........................................................682 Pressure Checks................................................................682 Brake Cooling Circuit Test.....................................................682 Power Up Relief Pressure Test..................................................683 Adjustment.....................................................................683 Power Down Relief Pressure Test................................................684 Adjustment.....................................................................684 Hoist Counterbalance Valve Adjustment..........................................685 HYDRAULIC SYSTEM FLUSHING PROCEDURE....................................................686 Preparation........................................................................686 Flushing Procedure.................................................................686 Filter Element Replacement.........................................................687 930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET....................................689 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX..................................................691 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX..................................................693 FIRE CONTROL SYSTEM (MANUAL)...........................................................695 Operation..........................................................................695 Inspection and Maintenance.........................................................695 Recharging Procedures..............................................................696 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1...........................697 Control Module.....................................................................697 Actuator...........................................................................698 Linear Detection Wire..............................................................698 Power Wire.........................................................................698 Test Kit...........................................................................698 Squib..............................................................................698 Securing the Detection Wire........................................................699 Preliminary Test Before Final Hook-Up..............................................699 Installation Procedure for Squib...................................................701 Placing the Electric Detection & Actuation System Into Service.....................701 INSPECTION AND MAINTENANCE SCHEDULES...............................................702 Daily..........................................................................702 Normal Maintenance Based On Actual Operating Hours.............................702 IN CASE OF FIRE....................................................................703 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM..........................................705 POSSIBLE CAUSES....................................................................705 SUGGESTED CORRECTIVE ACTION........................................................705 TROUBLE: Test Module Light Will Not Illuminate.....................................705 POSSIBLE CAUSES....................................................................705 SUGGESTED CORRECTIVE ACTION........................................................705 TROUBLE: Test Module Light Will Not Go Out.........................................705 POSSIBLE CAUSES....................................................................705 SUGGESTED CORRECTIVE ACTION........................................................705 TROUBLE: Detonated Squib...........................................................705 POSSIBLE CAUSES....................................................................705 SUGGESTED CORRECTIVE ACTION........................................................705 SECTION M8 - SPECIAL TOOLS.................................................................707 SECTION M20 - PAYLOAD METER II (ON BOARD WEIGHING SYSTEM) - INDEX..........................713 LIGHTS, SWITCHES AND COMPONENTS........................................................716 TIPS FOR OPERATION.....................................................................717 EXTERNAL DISPLAY LIGHTS................................................................717 THEORY OF OPERATION....................................................................718 Basic Description..................................................................718 Inclinometer.......................................................................718 Linkage Factor.....................................................................718 Gain Factor........................................................................719 Brake Lock.........................................................................719 Sources of Error...................................................................719 Typical Data From Service Check Mode...............................................719 Example Calculation of Payload.....................................................720 Viewing Payload Calculation Inputs.................................................720 Checking the Gain..................................................................721 Adjusting the Gain.................................................................721 TYPES OF DATA STORED...................................................................722 Cycle Data.........................................................................722 Engine ON/OFF Data.................................................................723 Fault Codes and Warning Data.......................................................723 Engine Operation...................................................................724 Total Payload and Total Number of Cycles...........................................724 Other Data.........................................................................724 OPERATOR FUNCTIONS.....................................................................725 Using the Operator Load Counter....................................................725 Viewing the Operator Load Counter..................................................725 Clearing the Operator Load Counter.................................................725 Dimming the Lights on the Display..................................................725 INITIAL SETUP OF PAYLOAD METER.........................................................726 Switch Settings....................................................................726 Checking the Operator Check Mode...................................................727 Checking the Service Check Mode....................................................727 Checking the Gt setting:...........................................................728 Checking the Inclinometer Settings.................................................728 Calibrating a Truck................................................................728 DISPLAYS AT START-UP...................................................................729 Normal Operation...................................................................729 SETUP AND MAINTENANCE..................................................................730 Setting The Speed Limit............................................................730 Setting the Option Code............................................................730 Setting The Machine I.D. Code......................................................731 Setting The Operator I.D. Code.....................................................731 Setting The Time and Date..........................................................731 DOWNLOAD OF INFORMATION................................................................732 DISPLAY OF FAULT CODES.................................................................732 Monitoring Input Signals...........................................................736 Service Check Mode.................................................................736 UP FACTOR - PAYLOAD CALCULATION GAIN...................................................737 PL MODE -LOAD CALCULATION TIMING.......................................................737 FINAL GEAR RATIO SELECTION.............................................................738 BATTERY REPLACEMENT PROCEDURE..........................................................739 Replacing the Battery..............................................................739 After Replacing the Battery........................................................740 SUSPENSION PRESSURE SENSOR.............................................................740 Removal............................................................................740 Installation.......................................................................741 INCLINOMETER...........................................................................741 Removal............................................................................741 Installation.......................................................................741 Adjustment.........................................................................741 PAYLOAD METER BACK PANEL...............................................................742 CONNECTIONS............................................................................743 GENERAL INFORMATION....................................................................715 Haul Cycles........................................................................715 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE..........................................744 PAYLOAD CIRCUIT NUMBERS................................................................745 TROUBLESHOOTING........................................................................746 COMMON PROBLEMS....................................................................746 Suspension Charging............................................................746 Symptom Table..................................................................747 Missing Body-Up Signal.........................................................747 Missing Speed Signal...........................................................748 F-18: Alternator R-Terminal, Oil Pressure Signals..............................748 Shorted 18v Sensor Power Supply (930E).........................................748 FAULT TREE DIAGNOSIS...............................................................749 Payload Lights Won't Illuminate................................................749 Red, Amber or Green Payload Light Does Not Illuminate..........................750 Cannot Download - PC Communications............................................751 PC Communications Configuration................................................752 F.CAL: Payload Meter Won't Calibrate...........................................753 F-20: Sensor Power Fault.......................................................754 F-21, F-25: Left Front Pressure Sensor.........................................756 F-22, F-26: Right Front Pressure Sensor........................................756 F-23, F-27: Left Rear Pressure Sensor..........................................756 F-24, F-28: Right Rear Pressure Sensor.........................................756 F-31, F-32: Inclinometer.......................................................758 Body Up Input..................................................................760 Brake Lock Input...............................................................761 Speed Signal...................................................................762 Adjusting the Speed Sensor.....................................................762 CONNECTORS AND PRESSURE SENSORS....................................................764 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM............................................767 Menu Functions.....................................................................770 Using Scope........................................................................770 Log File Information...............................................................770 Connections to Payload Meter II™...................................................771 USING SCOPE............................................................................772 Monitoring Inputs Using Scope......................................................772 Monitoring Suspension Charging Using Scope.........................................772 Pressure Sensor Dummy Loads........................................................775 GAIN ADJUSTMENT WORKSHEET..............................................................776 SECTION N - CAB COMPONENTS - INDEX.............................................................777 SECTION N2 - TRUCK CAB - INDEX.............................................................779 TRUCK CAB..............................................................................781 Description........................................................................781 Preparation........................................................................782 Removal - Cab......................................................................782 Installation - Cab.................................................................784 CAB DOOR...........................................................................784 Removal........................................................................784 Installation...................................................................784 Door Adjustment................................................................785 Door Jamb Bolt Adjustment......................................................785 Door Handle Plunger Adjustment.................................................786 Door Glass Replacement.........................................................787 Door Window Regulator Replacement..............................................791 Door Handle or Latch Assembly Replacement......................................791 Door and Door Hinge Seal Replacement...........................................792 Door Opening Seal Removal......................................................792 Installation...................................................................792 GLASS REPLACEMENT..................................................................793 Adhesive Bonded Windows........................................................793 Replacement Procedure..........................................................793 Windshield And Rear Glass......................................................794 Removal........................................................................794 Installation...................................................................795 SECTION N3 - CAB COMPONENTS - INDEX........................................................797 CAB COMPONENTS.........................................................................799 WINDSHIELD WIPERS..................................................................799 Wiper Motor Replacement........................................................799 Removal........................................................................799 Installation...................................................................799 Wiper Arm Replacement..........................................................799 Removal........................................................................799 Installation...................................................................800 Wiper Linkage Replacement......................................................800 Removal........................................................................800 Installation...................................................................800 WINDSHIELD WASHER..................................................................801 Operation......................................................................801 Service........................................................................801 OPERATOR SEAT......................................................................802 Adjustment.....................................................................802 Removal........................................................................802 Installation...................................................................802 SECTION N4 - OPERATOR COMFORT - INDEX......................................................803 OPERATOR COMFORT.......................................................................805 HEATER/AIR CONDITIONER.............................................................805 Operation......................................................................805 HEATER COMPONENTS..................................................................806 Circuit Breakers...............................................................806 Heater Control Components......................................................806 Heater Coil....................................................................806 Fan Motor And Speed Control....................................................807 Actuators......................................................................807 Filter Service.................................................................807 AIR CONDITIONING SYSTEM................................................................809 Environmental Impact...............................................................809 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES..........................................810 PRINCIPLES OF REFRIGERATION........................................................810 Air Conditioning...............................................................810 Refrigeration - The Act Of Cooling.............................................811 The Refrigeration Cycle........................................................811 AIR CONDITIONER SYSTEM COMPONENTS..................................................812 Compressor (Refrigerant Pump)..................................................812 Service Valves.................................................................812 Condenser......................................................................812 Receiver-Drier.................................................................812 Expansion Block Valve..........................................................813 Accumulator....................................................................813 Evaporator.....................................................................813 ELECTRICAL CIRCUIT.................................................................814 Thermostat.....................................................................814 Compressor Clutch..............................................................814 Trinary™ Switch................................................................815 SYSTEM SERVICING...................................................................816 SERVICE TOOLS AND EQUIPMENT........................................................817 Recovery/Recycle Station.......................................................817 Leak Detector..................................................................817 Service Valves.................................................................818 Vacuum Pump....................................................................818 Manifold Gauge Set.............................................................819 Installing Manifold Gauge Set..................................................820 Purging Air From Service Hoses.................................................820 SYSTEM PERFORMANCE TEST............................................................821 SYSTEM OIL.........................................................................822 Handling and Reusing PAG Oil...................................................822 Oil Quantity...................................................................822 Checking System Oil............................................................822 REFRIGERANT........................................................................823 Recycled Refrigerant...........................................................823 Reclaimed Refrigerant..........................................................823 Refrigerant Quantity...........................................................823 R-134a Refrigerant Containers..................................................823 SYSTEM LEAK TESTING................................................................824 Electronic Leak Detector.......................................................824 Tracer Dyes....................................................................824 Soap and Water.................................................................824 RECOVERING AND RECYCLING THE REFRIGERANT...........................................825 Performing the Recovery Cycle..................................................825 Performing the Recycling Procedure.............................................825 Evacuating and Charging the A/C System.........................................825 SYSTEM REPAIR......................................................................826 System Flushing................................................................826 COMPONENT REPLACEMENT..............................................................826 Hoses and Fittings.............................................................826 Lines..........................................................................826 Expansion Valve................................................................827 Receiver-Drier.................................................................827 Thermostat.....................................................................827 Compressor.....................................................................827 Accumulator....................................................................827 Clutch.........................................................................828 Servicing the Compressor Clutch................................................828 Pulley Removal.................................................................830 Clutch Coil Check..............................................................831 Pulley Installation............................................................831 Clutch Assembly Installation...................................................831 EVACUATING THE SYSTEM..............................................................833 CHARGING THE A/C SYSTEM............................................................835 TROUBLESHOOTING........................................................................836 Preliminary Checks.................................................................836 Diagnosis Of Gauge Readings And System Performance.................................836 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.........................................837 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM.......................................843 SECTION N5 - OPERATOR CAB CONTROLS - INDEX.................................................845 OPERATOR CAB CONTROLS..................................................................847 STEERING COLUMN....................................................................847 Removal........................................................................847 Installation...................................................................847 STEERING WHEEL AND CONTROLS........................................................849 HORN BUTTON....................................................................849 TELESCOPE LOCK RING............................................................849 TILT WHEEL LEVER...............................................................849 TURN SIGNAL / HEADLIGHT DIMMER.................................................849 DYNAMIC RETARDING..................................................................849 RETARDER CONTROL LEVER.........................................................850 DYNAMIC RETARDER/SERVICE BRAKE PEDAL...........................................850 ACCELERATOR (THROTTLE) PEDAL...................................................850 Starting on a Grade With a Loaded Truck........................................850 GRADE/SPEED RETARD CHART...........................................................851 HEATER / AIR CONDITIONER VENTS.....................................................852 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS..................................852 DEFROSTER VENT CONTROL SWITCH..................................................852 HEAT VENT CONTROL SWITCH.......................................................852 FAN CONTROL KNOB...............................................................852 AIR CONDITIONER CONTROL KNOB...................................................852 OUTSIDE/INSIDE AIR CONTROL SWITCH..............................................852 SELECTION CONTROL SWITCH.......................................................852 HEATER/AIR CONDITIONER VENTS...................................................852 INSTRUMENT PANEL...................................................................853 OVERHEAD PANEL AND DISPLAYS........................................................853 CENTER CONSOLE.....................................................................854 F-N-R SELECTOR SWITCH..........................................................854 HOIST CONTROL LEVER............................................................855 To Raise dump body:............................................................855 To lower body:.................................................................855 ASH TRAY.......................................................................855 LIGHTER........................................................................855 L.H. WINDOW CONTROL SWITCH.....................................................855 R.H. WINDOW CONTROL SWITCH.....................................................855 ENGINE SHUTDOWN SWITCH.........................................................855 OVERRIDE /FAULT RESET SWITCH...................................................856 10, FIGURE 5-5 - BLANK.........................................................856 RETARD SPEED CONTROL (RSC) "OFF/ON" SWITCH.....................................856 RETARD SPEED CONTROL (RSC) ADJUST DIAL.........................................856 INSTRUMENT PANEL AND INDICATOR LIGHTS..................................................859 CONTROL SYMBOLS....................................................................859 INSTRUMENT PANEL (Figure 5-6)......................................................859 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)....................................861 Starting...........................................................................861 Cold Weather Starting..............................................................861 Normal Engine Shutdown.............................................................861 Operation..........................................................................862 STATUS / WARNING INDICATOR LIGHT SYMBOLS...............................................868 SECTION P - LUBRICATION AND SERVICE - INDEX....................................................875 SECTION P2 - LUBRICATION AND SERVICE - INDEX...............................................877 LUBRICATION AND SERVICE................................................................879 930E SERVICE CAPACITIES............................................................879 HYDRAULIC TANK SERVICE.............................................................879 Adding Oil.....................................................................879 WHEEL MOTOR SERVICE................................................................879 COOLANT LEVEL CHECK................................................................880 RADIATOR FILLING PROCEDURE.........................................................880 LUBRICATION CHART..................................................................881 10 HOUR (DAILY) INSPECTION.........................................................882 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................885 100 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................886 250 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................887 500 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................890 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS......................................891 5000 HOUR MAINTENANCE CHECKS.......................................................892 SECTION P3 - LINCOLN AUTOMATIC LUBRICATION SYSTEM - INDEX..................................893 LINCOLN AUTOMATIC LUBRICATION SYSTEM...................................................895 System Components..................................................................895 System Operation...................................................................897 GENERAL INSTRUCTIONS...............................................................898 Lubricant Required for System..................................................898 System Priming.................................................................898 SYSTEM CHECKOUT....................................................................898 24 VDC SOLID STATE TIMER CHECK.....................................................899 24 VDC Solid State Timer Adjustment............................................899 INJECTORS (SL-1 Series "H")........................................................900 Injector Specifications........................................................900 Injector Adjustment............................................................900 INJECTOR OPERATION.................................................................901 PUMP CYCLE TIMER (FLASHER TIMER)...................................................902 Pump Cycle Timer (Flasher Timer) Installation..................................902 Pump Cycle Timer (Flasher Timer) Adjustment:...................................902 Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (N.C.).................902 PRESSURE REDUCER ADJUSTMENT........................................................904 TROUBLESHOOTING CHART..................................................................905 Preventative Maintenance Procedures....................................................908 Daily Lubrication System Inspection................................................908 250 Hour Inspection................................................................908 SECTION Q ALPHABETICAL INDEX...................................................................909 SECTION R......................................................................................913 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH348...................................................915 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH337.......................................916 ELECTRICAL SCHEMATIC - EG7500..............................................................917 24 VOLT ELECTRICAL SCHEMATIC - HE464.......................................................930 ENGINE RUN AND START ELECTRICAL SCHEMATIC - HE460..........................................945
KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL A30733-A30815 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
1 review for Komatsu 830E Dump Truck Operation & Maintenance Manual A30733-A30815 – PDF DOWNLOAD
Add a review
Kylian Quinton –