Komatsu 830E Dump Truck Operation & Maintenance Manual CEAM015001 – PDF DOWNLOAD

Description

Komatsu 830E Dump Truck Operation & Maintenance Manual CEAM015001 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E Dump Truck Operation & Maintenance Manual CEAM015001 – PDF DOWNLOAD

Language : English
Pages :947
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 830E Dump Truck Operation & Maintenance Manual CEAM015001 – PDF DOWNLOAD

SERIAL NUMBERS A30733 – A30815

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 CEAM015001 – PDF DOWNLOAD

SERIAL NUMBERS A30733 – A30815

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 SYSTEM100
FUEL RECEIVER100
TANK BREATHER VALVE100
Removal100
Installation100
Disassembly100
Assembly100
LEFT SIDE FILL101
FUEL – WATER SEPARATOR102
Installation102
Filter Service103
Backflushing Procedure103
Filter Element Replacement103
SECTION C – ENGINE – INDEX105
SECTION C2 – POWER MODULE – INDEX107
Preparation109
Preparation for Removal110
Power Module Removal113
Power Module Installation115
Power Module Hookup115
Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul)117
SECTION C3 – COOLING SYSTEM – INDEX119
COOLING SYSTEM121
COOLING SYSTEM DESCRIPTION121
Coolant Flow121
RADIATOR122
Removal122
RADIATOR REPAIR124
Internal Inspection124
External Cleaning124
Disassembly125
Cleaning and Inspection126
Assembly126
Pressure Testing127
Additional Service Information127
Installation128
RADIATOR FILL PROCEDURE128
Radiator Pressure Regulator Valve129
COOLING SYSTEM TROUBLESHOOTING129
SECTION C4 – POWERTRAIN – INDEX131
POWER TRAIN133
ALTERNATOR REMOVAL PROCEDURE133
Removal (MTU/DDC 4000 Engine)133
ENGINE/ALTERNATOR MATING135
General Instructions135
MEASURING PROCEDURE135
Joining Alternator and MTU/DDC Engine137
ENGINE138
Removal138
Service138
Installation138
SECTION C5 – AIR CLEANERS – INDEX139
AIR CLEANERS141
AIR CLEANERS141
Operation141
General Service Information141
FILTER ELEMENT REPLACEMENT142
Main Filter Element Cleaning143
Precleaner Section144
Cleaning Precleaner Tubes144
AIR INTAKE TROUBLESHOOTING145
SECTION C7 – FAN CLUTCH – INDEX147
FAN CLUTCH149
REMOVAL & INSTALLATION TOOLING149
FAN CLUTCH – DISASSEMBLY152
CLEANING AND INSPECTION162
ASSEMBLY – FAN CLUTCH166
TEST PROCEDURE180
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX181
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX 183
24VDC ELECTRIC SUPPLY SYSTEM185
ELECTRICAL SYSTEM DESCRIPTION185
BATTERIES185
Maintenance and Service185
Troubleshooting185
BATTERY SUPPLY SYSTEM187
24VDC Battery Charging Alternator187
Battery Box187
Battery Control Box187
System Battery Starter Disconnect Relay187
Battery Disconnect Switches188
24VDC Auxiliary Battery Connectors188
Battery Equalizer189
Troubleshooting189
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX191
24 VDC ELECTRICAL SYSTEM COMPONENTS193
PASSENGER SEAT BASE COMPARTMENT193
TRUCK SHUTDOWN PROCEDURE193
COMPONENTS193
Tail Light Resistor Diode Assemblies193
5 Minute Idle Timer Components193
Inclinometer195
Brake Warning Buzzer (BWB)195
Alarm Indicating Device (AID) System195
ELECTRICAL INTERFACE CABINET198
Lubrication System Timer198
Barometric Pressure Transducer198
Special Interface Module198
Power Distribution Terminals198
Truck Control Interface Panel198
Control Power Relay198
Circuit Breaker Panel198
Diode Board – DB1200
Diode Testing200
RELAY BOARDS201
Relay Boards – RB1, RB2, RB3, RB4, RB5201
Service201
Relay Board Identification202
Relay Board Functions203
Relay Board 6 (RB6)204
BODY-UP SWITCH205
Operation205
Adjustment205
Service205
HOIST LIMIT SWITCH206
Operation206
Adjustment206
Service206
SECTION D5 – DDEC ELECTRONIC ENGINE CONTROL – INDEX209
DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE211
COMPONENT DESCRIPTION212
Electronic Control Module212
Electronic Unit Nozzles214
System Sensors and Operator Inputs214
ENGINE PROTECTION SYSTEM215
DIAGNOSTICS216
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX217
BATTERY CHARGING ALTERNATOR219
ELECTRICAL SYSTEM DESCRIPTION219
BATTERY219
Maintenance and Service219
Troubleshooting219
BATTERY CHARGING SYSTEM (Niehoff)221
General Description221
TROUBLESHOOTING PROCEDURES (On-Truck)221
Equipment Required:221
Preliminary Checks222
Test Setup222
Test Procedure222
Regulator Bypass Test223
ON VEHICLE TROUBLESHOOTING GUIDE225
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage225
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:225
CHARGE VOLT AND AMP VALUES226
DEFINITIONS226
ADVANCED SYSTEM TROUBLESHOOTING227
Static Test – Engine OFF, Key ON, Battery Switch ON227
Go To Alternator227
Go To Regulator (If Required)228
Go To Regulator Connector On The Alternator228
ALTERNATOR OVERHAUL229
ALTERNATOR DIMENSIONS229
ALTERNATOR SPECIFICATIONS230
SERVICE PARTS231
ON-VEHICLE TEST233
Equipment:233
Preliminary Checks:233
Test Set-up233
Test Procedure233
ON-VEHICLE TEST234
Bypass Test:234
BENCH TEST235
STATIC TESTS236
Regulator Tests236
Control Box Tests237
ALTERNATOR DISASSEMBLY239
ASSEMBLY- ALTERNATOR244
BF4822 STATOR SERVICE TOOL INSTRUCTIONS253
Stator Removal And Replacement253
Stator Installation254
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX257
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX259
ELECTRICAL PROPULSION SYSTEM COMPONENTS261
GENERAL SYSTEM DESCRIPTION261
SYSTEM COMPONENTS263
Auxiliary Blower System263
Propulsion System Controller (PSC)263
TRUCK CONTROL INTERFACE PANEL (TCI)264
Diagnostic Information Display265
DID PANEL EVENT CODES265
PSC SOFTWARE FUNCTIONS290
Input Processing290
STATE MANAGEMENT290
State Machine290
Transitions Between States291
DC Link State293
Powering the Link293
De-Powering the Link293
Control Functions293
Engine Control293
ALTERNATOR FIELD CONTROL294
Desired Three-Phase Voltage294
Desired DC Link Voltage294
Self-load294
Propel Torque Control295
Retard Torque Control295
Wheel Slide Control295
Resistor Grid Control296
Chopper Voltage Control296
AUXILIARY BLOWER CONTROL296
EVENT PROCESSING296
Event Detection296
Power On Tests296
Initiated Tests297
Periodic Tests297
EVENT RESTRICTIONS297
EVENT LOGGING AND STORAGE297
Event History Buffer298
Data Packs298
To Record and Save a Data Pack to a Floppy Disk298
Event Reset299
SERIAL DATA COMMUNICATIONS300
PSC – TCI Communications processing300
PSC – PTU Communications Processing300
Inverter Communications Processing300
OUTPUT PROCESSING301
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS301
Fast Start301
Engine Shutdown/Engine Not Running301
Limp Home Mode301
Entering/Exiting Limp Home Mode301
PROPULSION SYSTEM COMPONENT ABBREVIATIONS302
ELECTRONIC ACCELERATOR AND RETARD PEDALS312
Removal312
Installation312
Disassembly312
Assembly312
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX313
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE315
AC DRIVE SYSTEM MAINTENANCE315
TRUCK SHUTDOWN PROCEDURES315
NORMAL TRUCK SHUTDOWN PROCEDURE316
SHUTDOWN AFTER SYSTEM FAILURE317
SYSTEM CHECKOUT318
Battery and Control Checks of System WITH Battery Power OFF318
Battery and Control Circuit Checks of System With Battery Power ON321
Checks with Key Switch OFF322
CPU Battery Checks324
MEMORY BACKUP BATTERY REPLACEMENT324
TCI PROGRAMMING325
PSC PROGRAMMING325
INVERTER PROGRAMMING326
TCI CHECKOUT326
Modular Mining Communication Port327
TCI Input Checks328
TCI Digital Output Tests330
TCI Digital Input Tests332
PSC Checkout Procedure334
PSC Digital Input Checks338
Miscellaneous Checks339
A3PV Panel339
LINKV Panel339
Thermistor Checks339
17FM384 Panel Check339
Pedal Percentages and Meter Calibration340
Meter Calibration Procedure340
Reprogram With Serial Numbers and Pedal Percentages342
LOAD TESTING344
Preload Checks344
ADDITIONAL TRUCK CHECKS346
On-Board Load Testing348
Preparation348
Initiate Loadbox Test351
Manual Offset HP Output Adjustment353
TROUBLESHOOTING355
PVM Optimum Load Curve Handshaking Troubleshooting355
MISCELLANEOUS COMPONENT REPAIR356
Troubleshooting Phase Modules and Chopper Modules356
Phase Module Removal and Snubber Resistor Replacement356
Snubber Resistor Installation357
Phase Module Installation357
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING358
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING361
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING362
IGBT TROUBLESHOOTING363
SECTION G – REAR AXLE, SPINDLE, AND WHEELS – INDEX365
SECTION G2 – TIRES AND RIMS – INDEX367
TIRES AND RIMS369
WHEEL STUD MAINTENANCE370
FRONT TIRES AND RIMS371
Removal371
Installation372
REAR TIRES AND RIMS373
Removal373
Installation374
RIM375
Tire Removal375
Tire Installation376
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX379
FRONT WHEEL HUB AND SPINDLE381
WHEEL HUB AND SPINDLE ASSEMBLY381
Preparation381
Removal381
Installation – Wheel Hub and Spindle Assembly384
Disassembly – Wheel Hub and Spindle Assembly385
Cleaning and Inspection – Wheel Hub and Spindle Assembly385
Assembly – Wheel Hub and Spindle Assembly387
Wheel Bearing Adjustment:387
Brake Installation388
Seal Assembly Gap Check389
STEERING CYLINDERS AND TIE ROD390
Spherical Bearing Wear Limits390
Removal – Steering Cylinder and Tie Rod391
Installation – Steering Cylinder and Tie Rod392
Bearing Replacement392
TOE-IN ADJUSTMENT393
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX395
REAR AXLE HOUSING ATTACHMENT397
PIVOT PIN397
Removal397
Installation397
PIVOT EYE BEARING398
Disassembly398
Assembly398
PIVOT EYE REPAIR399
Removal399
Disassembly399
Assembly399
Installation399
ANTI-SWAY BAR400
Removal400
Installation400
Disassembly400
Cleaning and Inspection400
Assembly400
SECTION G5 – REAR AXLE HOUSING – INDEX401
REAR AXLE HOUSING403
REAR AXLE HOUSING403
Preparation403
Removal403
Cleaning and Inspection – Rear Axle Housing405
Installation – Rear Axle Housing405
WHEEL MOTOR406
Preparation406
Removal406
Cleaning and Inspection – Wheel Motor407
Installation – Wheel Motor408
WHEEL MOTOR GEAR OIL411
Filtering Requirements411
Particle Size Analysis411
Flushing411
Oil Sample Analysis412
ELEMENT SPECIFICATION CHARTS413
SECTION H – HYDRAIR II SUSPENSIONS – INDEX417
SECTION H2 – FRONT SUSPENSIONS – INDEX419
FRONT SUSPENSION421
Removal421
Installation – Front Suspension422
“Turn-Of-The-Nut” Tightening Procedure425
MINOR REPAIRS (LOWER BEARING & SEALS)426
Removal – Bearing Retainer426
Installation – Bearing Retainer426
MAJOR SUSPENSION REBUILD428
Disassembly428
Assembly428
SECTION H3 – REAR SUSPENSIONS – INDEX431
REAR SUSPENSIONS433
Removal433
Installation – Rear Suspension435
Disassembly – Rear Suspension436
Cleaning and Inspection – Rear Suspension436
Assembly – Rear Suspension436
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX439
SUSPENSION OILING AND CHARGING PROCEDURE441
GENERAL441
EQUIPMENT LIST441
Hydrair® Charging Kit441
Installation of Charging Kit441
Removal of Charging Kit442
Support Blocks For Oiling And Charging Dimensions442
FRONT SUSPENSION443
Front Suspension Oiling443
Front Suspension Nitrogen Charging444
REAR SUSPENSION445
Rear Suspension Oiling445
Rear Suspension Nitrogen Charging446
OIL AND NITROGEN SPECIFICATIONS CHART448
SECTION J – BRAKE CIRCUIT – INDEX449
SECTION J2 – BRAKE CIRCUIT – INDEX451
BRAKE CIRCUIT453
SERVICE BRAKE CIRCUIT453
SECONDARY BRAKING AND AUTOMATIC APPLY455
PARKING BRAKE CIRCUIT455
BRAKE LOCK CIRCUIT456
WARNING CIRCUIT456
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX459
BRAKE CIRCUIT COMPONENT SERVICE461
BRAKE VALVE461
Rebuild Criteria461
Removal – Brake Valve462
Installation – Brake Valve462
Disassembly – Brake Valve463
Cleaning and Inspection – Brake Valve466
Assembly – Actuator Base Threaded Inserts466
Assembly – Boot and Cap466
Installation – Valve Body Seal466
Installation – Regulator Sleeve O-Ring467
Installation – Actuator Plunger O-ring467
Assembly – Brake Valve467
DIFFERENTIAL PRESSURE SWITCH469
Disassembly469
Cleaning and Inspection469
Assembly469
VALVE BENCH TEST AND ADJUSTMENT470
Test Set Up Procedure471
Adjustment – Brake Valve Output Pressure471
Adjustment – Differential Pressure Switch471
Final Test and Adjustment472
Installation – Brake Pedal Actuator Assembly to Brake Valve473
Installation – Retard Pedal To Brake Pedal473
DUAL RELAY VALVE475
Removal475
Installation475
Disassembly – Dual Relay Valve477
Cleaning and Inspection – Dual Relay Valve477
Assembly – Dual Relay Valve477
DIFFERENTIAL PRESSURE SWITCH478
Disassembly478
Cleaning and Inspection478
Assembly478
VALVE TEST AND ADJUSTMENT479
Test Set Up Procedure480
Adjustment – Brake Valve Output Pressure480
Adjustment – Differential Pressure Switch481
BRAKE MANIFOLD482
Removal482
Installation483
Disassembly483
Cleaning and Inspection483
Assembly483
HYDRAULIC BRAKE ACCUMULATORS484
Brake Accumulator Bleed Down Procedure484
ACCUMULATORS – HYDRAULIC COMPONENT CABINET484
Removal484
Installation484
Disassembly484
Cleaning and Inspection486
Assembly486
BLADDER ACCUMULATOR CHARGING PROCEDURE488
Temperature During Precharge489
Precharge Maintenance489
Accumulator Storage Procedures490
Bladder Storage Procedures491
ACCUMULATORS – FRAME MOUNTED491
Removal491
Installation491
Disassembly493
Cleaning and Inspection493
Assembly – Accumulator494
Accumulator Testing494
ACCUMULATOR CHARGING PROCEDURE495
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)496
Removal – Retarder Control Lever496
Installation – Retarder Control Lever496
Disassembly and Adjustment – Retarder Control Lever497
Potentiometer Check – Retarder Control Lever497
Assembly – Retarder Control Lever497
SECTION J4 – BRAKE CIRCUIT CHECKOUT PROCEDURE – INDEX499
BRAKE CIRCUIT CHECK-OUT PROCEDURE501
EQUIPMENT REQUIRED503
INITIAL SYSTEM SET-UP504
BRAKE SYSTEM CHECKOUT505
Failure Modes Check-Out506
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING509
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET513
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX515
WET DISC BRAKE ASSEMBLY517
OPERATION517
MAINTENANCE518
Brake Disc Wear Indicator518
Removal/Installation – Wet Disc Brake Assembly518
BRAKE REBUILD520
Disassembly520
Cleaning and Inspection523
Assembly524
Floating Ring Seal Assembly/Installation527
WET DISC BRAKE BLEEDING PROCEDURE530
SECTION J7 – PARKING BRAKE – INDEX531
PARKING BRAKE533
OPERATION533
MAINTENANCE534
Inspection – Parking Brake534
Removal – Parking Brake534
Installation – Parking Brake535
Disassembly – Parking Brake536
Cleaning and Inspection – Parking Brake536
Assembly – Parking Brake536
PARKING BRAKE BLEEDING PROCEDURE538
SECTION L – HYDRAULIC SYSTEM – INDEX539
SECTION L2 – HYDRAULIC SYSTEM – INDEX541
HYDRAULIC SYSTEM543
Hoist Circuit Operation544
Steering Circuit Operation546
Disc Brake Cooling System548
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX551
HYDRAULIC SYSTEM COMPONENT REPAIR553
HOIST PUMP553
Removal553
Installation555
Disassembly556
Inspection Of Parts560
Assembly560
TROUBLESHOOTING GUIDE565
HYDRAULIC TANK566
Filling Instructions566
Removal566
Installation567
HYDRAULIC TANK STRAINERS567
Removal567
Inspect and Clean567
Installation567
Hydraulic Tank Breathers568
SECTION L4 – STEERING CIRCUIT – INDEX569
STEERING CIRCUIT571
STEERING CIRCUIT OPERATION571
COMPONENT DESCRIPTION572
Steering Control Valve572
Bleeddown Manifold Valve573
Bleeddown Solenoids573
Accumulators574
Low Precharge Warning Switch574
High Pressure Filter574
Flow Amplifier574
FLOW AMPLIFIER SYSTEM OPERATION576
No Steer576
Steering Left578
Steering Right580
No Steer, External Shock Load582
STEERING PUMP584
Operation584
High Altitude Operation584
PRINCIPLE OF OPERATION586
Steering Pump587
SECTION L5 – STEERING CONTROL UNIT – INDEX589
STEERING CONTROL UNIT591
Removal591
Installation591
STEERING CONTROL UNIT REBUILD592
Disassembly592
Cleaning and Inspection – Steering Control Unit593
Assembly – Steering Control Unit595
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX599
STEERING CIRCUIT COMPONENT REPAIR601
BLEEDDOWN MANIFOLD VALVE601
Removal601
Installation601
ACCUMULATORS602
Removal602
Installation602
Disassembly603
Cleaning and Inspection603
Assembly604
TESTING604
STEERING ACCUMULATOR CHARGING PROCEDURE605
FLOW AMPLIFIER606
Removal606
Installation606
FLOW AMPLIFIER REBUILD606
Disassembly608
Assembly609
STEERING CYLINDERS610
Disassembly611
Piston Seal & Bearing Installation611
Cylinder Assembly611
Test611
STEERING AND BRAKE PUMP612
Removal612
Installation612
Disassembly614
Control Piston Group614
Valve Plate Group614
Rotating Group617
Swashblock Group617
Driveshaft Group617
Inspection617
Control Piston Group617
Valve Plate Group617
Rotating Group617
Swashblock Group619
Driveshaft Group620
Compensator Block and Unloader Module620
Stroke Adjuster Assembly620
Assembly620
Swashblock Group620
Driveshaft Group621
Rotating Group621
Control Piston Group621
Valve Plate Group622
TROUBLESHOOTING CHART623
SECTION L7 – HOIST CIRCUIT – INDEX629
HOIST CIRCUIT631
HOIST CIRCUIT OPERATION631
COMPONENT DESCRIPTION632
Hydraulic Tank632
Hydraulic Pump632
High Pressure Filters632
Hoist Valve632
Inlet Sections632
Spool Sections633
Work Ports (Rear) Spool Section633
Tank Ports (Front) Spool Section633
Hoist Pilot Valve633
Hoist Up Limit Solenoid634
Pilot Operated Check Valve634
Snubber Valve634
Counterbalance Valve634
HOIST CIRCUIT OPERATION634
POWER UP OPERATION (Figure 7-5)636
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX645
HOIST CIRCUIT COMPONENT REPAIR647
HOIST VALVE647
Removal647
Installation648
O-Ring Replacement648
INLET SECTION649
Disassembly649
Cleaning and Inspection650
Assembly650
REAR SPOOL SECTION (Work Ports)650
Disassembly650
Cleaning and Inspection652
Assembly652
FRONT SPOOL SECTION (Tank Ports)653
Disassembly653
Cleaning and Inspection653
Assembly653
HOIST PILOT VALVE655
Removal655
Installation655
Disassembly656
Cleaning and Inspection657
Assembly657
HOIST – UP LIMIT SOLENOID VALVE658
HOIST CYLINDERS658
Removal658
Installation659
Disassembly661
Cleaning and Inspection662
ASSEMBLY OF QUILL AND CYLINDER663
Quill Installation663
Installation Of Check Balls And Plugs In Quill664
Assembly of Cylinder665
DISABLED TRUCK DUMPING PROCEDURE666
HOOKUP666
DUMPING PROCEDURE666
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX667
HYDRAULIC SYSTEM FILTERS669
HOIST CIRCUIT FILTER669
Filter Element Replacement669
Removal – Hoist Circuit Filter670
Installation – Hoist Circuit Filter670
Indicator Switch – Hoist Circuit Filter670
STEERING CIRCUIT FILTER671
Filter Element Replacement671
Removal – Steering Circuit Filter672
Installation – Steering Circuit Filter672
Indicator Switch – Steering Circuit Filter672
INDICATOR SWITCH672
Test Procedure672
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX675
HYDRAULIC CHECK-OUT PROCEDURE677
GENERAL INFORMATION677
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE677
Equipment Requirements678
Pump Pressure Control Adjustments678
Steering Control Valve and Flow Amplifier Leakage Test679
Bleeddown Manifold Leakage Test679
Steering / Brake Pump Stroke Adjustment680
Shock And Suction Valves681
Equipment Requirements681
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES682
Equipment Requirements682
Pressure Checks682
Brake Cooling Circuit Test682
Power Up Relief Pressure Test683
Adjustment683
Power Down Relief Pressure Test684
Adjustment684
Hoist Counterbalance Valve Adjustment685
HYDRAULIC SYSTEM FLUSHING PROCEDURE686
Preparation686
Flushing Procedure686
Filter Element Replacement687
930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET689
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX691
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX693
FIRE CONTROL SYSTEM (MANUAL)695
Operation695
Inspection and Maintenance695
Recharging Procedures696
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1697
Control Module697
Actuator698
Linear Detection Wire698
Power Wire698
Test Kit698
Squib698
Securing the Detection Wire699
Preliminary Test Before Final Hook-Up699
Installation Procedure for Squib701
Placing the Electric Detection & Actuation System Into Service701
INSPECTION AND MAINTENANCE SCHEDULES702
Daily702
Normal Maintenance Based On Actual Operating Hours702
IN CASE OF FIRE703
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM705
POSSIBLE CAUSES705
SUGGESTED CORRECTIVE ACTION705
TROUBLE: Test Module Light Will Not Illuminate705
POSSIBLE CAUSES705
SUGGESTED CORRECTIVE ACTION705
TROUBLE: Test Module Light Will Not Go Out705
POSSIBLE CAUSES705
SUGGESTED CORRECTIVE ACTION705
TROUBLE: Detonated Squib705
POSSIBLE CAUSES705
SUGGESTED CORRECTIVE ACTION705
SECTION M8 – SPECIAL TOOLS707
SECTION M20 – PAYLOAD METER II (ON BOARD WEIGHING SYSTEM) – INDEX713
LIGHTS, SWITCHES AND COMPONENTS716
TIPS FOR OPERATION717
EXTERNAL DISPLAY LIGHTS717
THEORY OF OPERATION718
Basic Description718
Inclinometer718
Linkage Factor718
Gain Factor719
Brake Lock719
Sources of Error719
Typical Data From Service Check Mode719
Example Calculation of Payload720
Viewing Payload Calculation Inputs720
Checking the Gain721
Adjusting the Gain721
TYPES OF DATA STORED722
Cycle Data722
Engine ON/OFF Data723
Fault Codes and Warning Data723
Engine Operation724
Total Payload and Total Number of Cycles724
Other Data724
OPERATOR FUNCTIONS725
Using the Operator Load Counter725
Viewing the Operator Load Counter725
Clearing the Operator Load Counter725
Dimming the Lights on the Display725
INITIAL SETUP OF PAYLOAD METER726
Switch Settings726
Checking the Operator Check Mode727
Checking the Service Check Mode727
Checking the Gt setting:728
Checking the Inclinometer Settings728
Calibrating a Truck728
DISPLAYS AT START-UP729
Normal Operation729
SETUP AND MAINTENANCE730
Setting The Speed Limit730
Setting the Option Code730
Setting The Machine ID Code731
Setting The Operator ID Code731
Setting The Time and Date731
DOWNLOAD OF INFORMATION732
DISPLAY OF FAULT CODES732
Monitoring Input Signals736
Service Check Mode736
UP FACTOR – PAYLOAD CALCULATION GAIN737
PL MODE -LOAD CALCULATION TIMING737
FINAL GEAR RATIO SELECTION738
BATTERY REPLACEMENT PROCEDURE739
Replacing the Battery739
After Replacing the Battery740
SUSPENSION PRESSURE SENSOR740
Removal740
Installation741
INCLINOMETER741
Removal741
Installation741
Adjustment741
PAYLOAD METER BACK PANEL742
CONNECTIONS743
GENERAL INFORMATION715
Haul Cycles715
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE744
PAYLOAD CIRCUIT NUMBERS745
TROUBLESHOOTING746
COMMON PROBLEMS746
Suspension Charging746
Symptom Table747
Missing Body-Up Signal747
Missing Speed Signal748
F-18: Alternator R-Terminal, Oil Pressure Signals748
Shorted 18v Sensor Power Supply (930E)748
FAULT TREE DIAGNOSIS749
Payload Lights Won’t Illuminate749
Red, Amber or Green Payload Light Does Not Illuminate750
Cannot Download – PC Communications751
PC Communications Configuration752
FCAL: Payload Meter Won’t Calibrate753
F-20: Sensor Power Fault754
F-21, F-25: Left Front Pressure Sensor756
F-22, F-26: Right Front Pressure Sensor756
F-23, F-27: Left Rear Pressure Sensor756
F-24, F-28: Right Rear Pressure Sensor756
F-31, F-32: Inclinometer758
Body Up Input760
Brake Lock Input761
Speed Signal762
Adjusting the Speed Sensor762
CONNECTORS AND PRESSURE SENSORS764
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM767
Menu Functions770
Using Scope770
Log File Information770
Connections to Payload Meter II™771
USING SCOPE772
Monitoring Inputs Using Scope772
Monitoring Suspension Charging Using Scope772
Pressure Sensor Dummy Loads775
GAIN ADJUSTMENT WORKSHEET776
SECTION N – CAB COMPONENTS – INDEX777
SECTION N2 – TRUCK CAB – INDEX779
TRUCK CAB781
Description781
Preparation782
Removal – Cab782
Installation – Cab784
CAB DOOR784
Removal784
Installation784
Door Adjustment785
Door Jamb Bolt Adjustment785
Door Handle Plunger Adjustment786
Door Glass Replacement787
Door Window Regulator Replacement791
Door Handle or Latch Assembly Replacement791
Door and Door Hinge Seal Replacement792
Door Opening Seal Removal792
Installation792
GLASS REPLACEMENT793
Adhesive Bonded Windows793
Replacement Procedure793
Windshield And Rear Glass794
Removal794
Installation795
SECTION N3 – CAB COMPONENTS – INDEX797
CAB COMPONENTS799
WINDSHIELD WIPERS799
Wiper Motor Replacement799
Removal799
Installation799
Wiper Arm Replacement799
Removal799
Installation800
Wiper Linkage Replacement800
Removal800
Installation800
WINDSHIELD WASHER801
Operation801
Service801
OPERATOR SEAT802
Adjustment802
Removal802
Installation802
SECTION N4 – OPERATOR COMFORT – INDEX803
OPERATOR COMFORT805
HEATER/AIR CONDITIONER805
Operation805
HEATER COMPONENTS806
Circuit Breakers806
Heater Control Components806
Heater Coil806
Fan Motor And Speed Control807
Actuators807
Filter Service807
AIR CONDITIONING SYSTEM809
Environmental Impact809
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES810
PRINCIPLES OF REFRIGERATION810
Air Conditioning810
Refrigeration – The Act Of Cooling811
The Refrigeration Cycle811
AIR CONDITIONER SYSTEM COMPONENTS812
Compressor (Refrigerant Pump)812
Service Valves812
Condenser812
Receiver-Drier812
Expansion Block Valve813
Accumulator813
Evaporator813
ELECTRICAL CIRCUIT814
Thermostat814
Compressor Clutch814
Trinary™ Switch815
SYSTEM SERVICING816
SERVICE TOOLS AND EQUIPMENT817
Recovery/Recycle Station817
Leak Detector817
Service Valves818
Vacuum Pump818
Manifold Gauge Set819
Installing Manifold Gauge Set820
Purging Air From Service Hoses820
SYSTEM PERFORMANCE TEST821
SYSTEM OIL822
Handling and Reusing PAG Oil822
Oil Quantity822
Checking System Oil822
REFRIGERANT823
Recycled Refrigerant823
Reclaimed Refrigerant823
Refrigerant Quantity823
R-134a Refrigerant Containers823
SYSTEM LEAK TESTING824
Electronic Leak Detector824
Tracer Dyes824
Soap and Water824
RECOVERING AND RECYCLING THE REFRIGERANT825
Performing the Recovery Cycle825
Performing the Recycling Procedure825
Evacuating and Charging the A/C System825
SYSTEM REPAIR826
System Flushing826
COMPONENT REPLACEMENT826
Hoses and Fittings826
Lines826
Expansion Valve827
Receiver-Drier827
Thermostat827
Compressor827
Accumulator827
Clutch828
Servicing the Compressor Clutch828
Pulley Removal830
Clutch Coil Check831
Pulley Installation831
Clutch Assembly Installation831
EVACUATING THE SYSTEM833
CHARGING THE A/C SYSTEM835
TROUBLESHOOTING836
Preliminary Checks836
Diagnosis Of Gauge Readings And System Performance836
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS837
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM843
SECTION N5 – OPERATOR CAB CONTROLS – INDEX845
OPERATOR CAB CONTROLS847
STEERING COLUMN847
Removal847
Installation847
STEERING WHEEL AND CONTROLS849
HORN BUTTON849
TELESCOPE LOCK RING849
TILT WHEEL LEVER849
TURN SIGNAL / HEADLIGHT DIMMER849
DYNAMIC RETARDING849
RETARDER CONTROL LEVER850
DYNAMIC RETARDER/SERVICE BRAKE PEDAL850
ACCELERATOR (THROTTLE) PEDAL850
Starting on a Grade With a Loaded Truck850
GRADE/SPEED RETARD CHART851
HEATER / AIR CONDITIONER VENTS852
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS852
DEFROSTER VENT CONTROL SWITCH852
HEAT VENT CONTROL SWITCH852
FAN CONTROL KNOB852
AIR CONDITIONER CONTROL KNOB852
OUTSIDE/INSIDE AIR CONTROL SWITCH852
SELECTION CONTROL SWITCH852
HEATER/AIR CONDITIONER VENTS852
INSTRUMENT PANEL853
OVERHEAD PANEL AND DISPLAYS853
CENTER CONSOLE854
F-N-R SELECTOR SWITCH854
HOIST CONTROL LEVER855
To Raise dump body:855
To lower body:855
ASH TRAY855
LIGHTER855
LH WINDOW CONTROL SWITCH855
RH WINDOW CONTROL SWITCH855
ENGINE SHUTDOWN SWITCH855
OVERRIDE /FAULT RESET SWITCH856
10, FIGURE 5-5 – BLANK856
RETARD SPEED CONTROL (RSC) “OFF/ON” SWITCH856
RETARD SPEED CONTROL (RSC) ADJUST DIAL856
INSTRUMENT PANEL AND INDICATOR LIGHTS859
CONTROL SYMBOLS859
INSTRUMENT PANEL (Figure 5-6)859
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)861
Starting861
Cold Weather Starting861
Normal Engine Shutdown861
Operation862
STATUS / WARNING INDICATOR LIGHT SYMBOLS868
SECTION P – LUBRICATION AND SERVICE – INDEX875
SECTION P2 – LUBRICATION AND SERVICE – INDEX877
LUBRICATION AND SERVICE879
930E SERVICE CAPACITIES879
HYDRAULIC TANK SERVICE879
Adding Oil879
WHEEL MOTOR SERVICE879
COOLANT LEVEL CHECK880
RADIATOR FILLING PROCEDURE880
LUBRICATION CHART881
10 HOUR (DAILY) INSPECTION882
50 HOUR LUBRICATION AND MAINTENANCE CHECKS885
100 HOUR LUBRICATION AND MAINTENANCE CHECKS886
250 HOUR LUBRICATION AND MAINTENANCE CHECKS887
500 HOUR LUBRICATION AND MAINTENANCE CHECKS890
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS891
5000 HOUR MAINTENANCE CHECKS892
SECTION P3 – LINCOLN AUTOMATIC LUBRICATION SYSTEM – INDEX893
LINCOLN AUTOMATIC LUBRICATION SYSTEM895
System Components895
System Operation897
GENERAL INSTRUCTIONS898
Lubricant Required for System898
System Priming898
SYSTEM CHECKOUT898
24 VDC SOLID STATE TIMER CHECK899
24 VDC Solid State Timer Adjustment899
INJECTORS (SL-1 Series “H”)900
Injector Specifications900
Injector Adjustment900
INJECTOR OPERATION901
PUMP CYCLE TIMER (FLASHER TIMER)902
Pump Cycle Timer (Flasher Timer) Installation902
Pump Cycle Timer (Flasher Timer) Adjustment:902
Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (NC)902
PRESSURE REDUCER ADJUSTMENT904
TROUBLESHOOTING CHART905
Preventative Maintenance Procedures908
Daily Lubrication System Inspection908
250 Hour Inspection908
SECTION Q ALPHABETICAL INDEX909
SECTION R913
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH348915
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH337916
ELECTRICAL SCHEMATIC – EG7500917
24 VOLT ELECTRICAL SCHEMATIC – HE464930
ENGINE RUN AND START ELECTRICAL SCHEMATIC – HE460945

IMAGES PREVIEW OF THE MANUAL:

S.M 16/12/24