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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX AFE32-DJ – AFE32-DM AFE32-DS & UP) KOMATSU 830E – PDF DOWNLOAD
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- KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL SUFFIX: AFE32-DJ – AFE32-DM AFE32-DS & UP
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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX AFE32-DJ – AFE32-DM AFE32-DS & UP) KOMATSU 830E
KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX AFE32-DJ – AFE32-DM AFE32-DS & UP) KOMATSU 830E – PDF DOWNLOAD:
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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX AFE32-DJ – AFE32-DM AFE32-DS & UP) KOMATSU 830E
- This Service Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly.
- Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
- The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque.
- All torque specifications have ± 10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The HAULPAK® Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX AFE32-DJ – AFE32-DM AFE32-DS & UP) KOMATSU 830E
COVER............................................................................................................................... 1 TABLE OF CONTENTS................................................................................................................... 5 SECTION A - GENERAL INFORMATION..................................................................................................... 7 GENERAL INFORMATION INDEX....................................................................................................... 7 GENERAL SAFETY AND OPERATION................................................................................................ 13 SAFETY IS THINKING AHEAD................................................................................................ 13 Safe practices start before the operator gets to the equipment!..................................................... 13 PREPARING FOR OPERATION................................................................................................. 13 ENGINE START-UP SAFETY PRACTICES........................................................................................ 14 AFTER ENGINE HAS STARTED................................................................................................ 15 SAFETY PRECAUTIONS DURING TRUCK OPERATION............................................................................... 15 LOADING................................................................................................................. 16 HAULING................................................................................................................. 17 PASSING................................................................................................................. 17 DUMPING................................................................................................................. 17 To Raise dump body:................................................................................................. 18 To Lower Body:...................................................................................................... 18 TOWING.................................................................................................................. 18 WHEN REPAIRS ARE NECESSARY.............................................................................................. 19 SAFE PARKING PROCEDURES................................................................................................. 20 SHUTDOWN PROCEDURE...................................................................................................... 20 STANDARD TORQUE CHARTS AND CONVERSION TABLES................................................................................ 27 STORAGE AND IDLE MACHINE PREPARATION........................................................................................ 33 SHORT TERM IDLE PERIODS..................................................................................................... 33 PREPARATION FOR STORAGE..................................................................................................... 34 REMOVAL FROM STORAGE.................................................................................................... 35 RECONDITIONING AN IDLE VEHICLE.......................................................................................... 37 ENGINE OPERATION........................................................................................................ 40 AFTER ENGINE HAS STARTED................................................................................................ 41 ENGINE STORAGE-CUMMINS.................................................................................................. 42 Engine Storage-(Short Term)......................................................................................... 42 Prepare the Engine for Short Term Storage........................................................................... 42 Remove the Engine from Short Term Storage........................................................................... 42 Engine Storage- (Long Term)......................................................................................... 43 6 Months to 24 Months............................................................................................... 43 Prepare the Engine for Long Term Storage............................................................................ 43 Remove the Engine from Long Term Storage............................................................................ 43 ENGINE STORAGE - DETROIT DIESEL......................................................................................... 44 Preparing Engine For Storage........................................................................................ 44 Temporary Storage (30 Days Or Less)................................................................................. 44 Extended Storage (more Than 30 Days)................................................................................ 44 PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE......................................... 46 ELECTRIC DRIVE TRUCKS................................................................................................... 47 Storage Instructions and Procedures................................................................................. 47 Placing Equipment Into Storage...................................................................................... 47 When Storing A Truck That Is Operational............................................................................ 47 When Storing A Truck That Is Not Operational........................................................................ 48 When Storing A Major Component...................................................................................... 48 Periodic Inspections................................................................................................ 49 Placing Equipment Into Service After Storage........................................................................ 49 When A Truck Is Operational......................................................................................... 49 When A Truck Is Not Operational..................................................................................... 49 For The First Hour.................................................................................................. 50 PRESERVATION AND STORAGE ALLISON TRANSMISSION........................................................................... 51 Storage, New Transmission........................................................................................... 51 Storage, One Year -- Without Oil.................................................................................... 51 Storage, One Year With Oil (normally in a vehicle chassis).......................................................... 51 Restoring Transmission to Service................................................................................... 51 SECTION B - STRUCTURES.............................................................................................................. 53 STRUCTURES INDEX................................................................................................................ 53 STRUCTURAL COMPONENTS....................................................................................................... 55 DUMP BODY................................................................................................................... 59 SECTION C - ENGINE.................................................................................................................. 65 ENGINE, FUEL, COOLING AND AIR CLEANER INDEX..................................................................................... 65 AIR FILTRATION SYSTEM....................................................................................................... 89 AIR CLEANER............................................................................................................. 89 Operation........................................................................................................... 89 General Service Information......................................................................................... 89 MAIN FILTER ELEMENT..................................................................................................... 89 Removal............................................................................................................. 89 Installation........................................................................................................ 90 SAFETY FILTER ELEMENT................................................................................................... 91 Removal............................................................................................................. 91 Installation........................................................................................................ 91 AIR INTAKE TROUBLESHOOTING.............................................................................................. 91 AIR CLEANER ASSEMBLY CLEANING........................................................................................... 91 Main Filter Cleaning................................................................................................ 91 Precleaner Section Cleaning......................................................................................... 92 SECTION D - ELECTRIC SYSTEM......................................................................................................... 95 ELECTRIC SYSTEM (24 VDC NON-PROPULSION) INDEX................................................................................... 95 24 VDC ELECTRIC SUPPLY SYSTEM............................................................................................... 97 ELECTRICAL SYSTEM DESCRIPTION........................................................................................... 97 BATTERY................................................................................................................. 97 Maintenance and Service............................................................................................. 97 Troubleshooting..................................................................................................... 97 BATTERY CHARGING SYSTEM (Used with DDC and Cummins Engines)............................................................. 98 General Description................................................................................................. 98 Operating Principles................................................................................................ 99 Energizing Speed....................................................................................................100 Rated Voltage.......................................................................................................100 Magnetizing The Rotor...............................................................................................100 INTEGRAL CHARGING SYSTEM (Battery Charging Alternator)..................................................................101 Troubleshooting Procedures..........................................................................................101 Integral Charging System Repair.....................................................................................101 Regulator Check.....................................................................................................102 Rectifier Bridge Check (Omit for Overcharged Battery)...............................................................102 Field Coil Checks...................................................................................................102 Diode Trio Check....................................................................................................103 Stator Checks (Omit for Overcharged Battery)........................................................................103 Disassembly (Refer to Figure 2-10)..................................................................................103 Reassembly..........................................................................................................104 SECTION E - ELECTRIC PROPULSION AND CONTROL.........................................................................................119 ELECTRICAL PROPULSION AND CONTROL INDEX.........................................................................................119 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.............................................................................195 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.........................................................................199 GENERAL INFORMATION.................................................................................................199 COMMUNICATIONS PORT CHECK...........................................................................................200 PTU Hookup......................................................................................................200 4.0 SEQUENCE TESTS - (ENGINE NOT ON)................................................................................201 Preparation and Setup...........................................................................................201 CONTROL SYSTEM SELF-TEST............................................................................................202 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT............................................................................202 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT..............................................................................203 PTU Setup.......................................................................................................203 4.3 REVERSER AND PROPULSION CONTACTORS CHECK........................................................................204 4.4 NOT USED........................................................................................................205 4.5 RETARD CONTACTORS OPERATION CHECK...............................................................................205 4.6 GROUND FAULT SENSING CHECK......................................................................................205 4.7 GROUND FAULT IN RETARD OPERATION CHECK..........................................................................206 4.8 OVERRIDE OPERATION CHECK........................................................................................206 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK...............................................................................207 4.10 OVERSPEED RETARD OPERATION CHECK...............................................................................207 4.11 HOIST INTERLOCK OPERATION CHECK................................................................................208 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.......................................................................208 Return to Main Menu.............................................................................................208 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL............................................................209 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU...................................................................209 5.2 DIGITAL INPUT CHECKS............................................................................................210 5.3 DIGITAL OUTPUT CHECKS...........................................................................................211 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL....................................................................215 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU........................................................................215 6.2 ANALOG INPUT CHECKS.............................................................................................216 6.3 FREQUENCY INPUT CHECKS..........................................................................................220 Return to Main Menu.............................................................................................221 7.0 SPEED EVENT CHECKS..............................................................................................221 Preparation and Setup...........................................................................................221 Setup PTU.......................................................................................................221 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK.........................................................222 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK..............................................222 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK.............................................222 7.4 OTHER SPEED EVENTS CHECKS.......................................................................................222 Return to Main Menu.............................................................................................222 8.0 RETARD SPEED CONTROL SYSTEM CHECK...............................................................................223 Preparation and Setup...........................................................................................223 Setup PTU.......................................................................................................223 8.1 OVERSPEED PICKUP AND DROPOUT CHECK..............................................................................223 8.2 RETARD POT MAXIMUM SETTING CHECK................................................................................223 8.3 RETARD POT MINIMUM SETTING CHECK................................................................................223 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL..............................................................224 Return to Main Menu.............................................................................................224 9.0 LOAD TEST USING TRUCK RETARD GRIDS..............................................................................224 Setup and Preparation...........................................................................................224 PTU Setup.......................................................................................................224 9.1 LOAD TEST.......................................................................................................225 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING.........................................................................225 Setup PTU.......................................................................................................225 10.1 RETARD CHECK...................................................................................................226 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT....................................................................227 11.1 BRAKE SYSTEM INTERLOCKS CHECK..................................................................................227 Preparation.....................................................................................................227 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT.........................................................................227 11.3 SYNC TRANSFORMER CHECKOUT......................................................................................228 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT.....................................................................228 11.5 BATTERY BOOST ADJUSTMENT.......................................................................................228 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST....................................................................228 11.7 MOTOR ROTATION TEST............................................................................................229 11.8 GROUND FAULT CHECKS............................................................................................229 12.0 MISCELLANEOUS CHARTS...........................................................................................230 12.1 WHEEL MOTOR GEAR RATIOS........................................................................................230 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS.................................................................................231 12.3 ENGINE OPTIONS.................................................................................................232 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE TABLE OF CONTENTS.......................................................233 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS.........................................................................................235 DRIVE AXLE, SPINDLE AND WHEELS INDEX............................................................................................235 TIRES AND RIMS..............................................................................................................237 FRONT TIRES AND RIMS....................................................................................................237 Removal.............................................................................................................237 Installation........................................................................................................238 REAR TIRES AND RIMS.....................................................................................................239 Removal.............................................................................................................239 Installation........................................................................................................240 RIM.....................................................................................................................241 Tire Removal........................................................................................................241 RIM AND TIRE PREPARATION................................................................................................241 LUBRICANTS..............................................................................................................242 TIRE INSTALLATION.......................................................................................................242 FRONT WHEEL HUB AND SPINDLE.................................................................................................245 WHEEL HUB AND SPINDLE ASSEMBLY..........................................................................................245 Removal.............................................................................................................245 Installation........................................................................................................247 Disassembly.........................................................................................................247 Cleaning and Inspection.............................................................................................248 Assembly............................................................................................................248 Wheel Bearing Adjustment (Tire Removed).............................................................................250 Wheel Bearing Adjustment (Tire mounted).............................................................................251 STEERING CYLINDERS AND TIE ROD..........................................................................................252 Removal.............................................................................................................252 Installation........................................................................................................252 Bearing Replacement.................................................................................................252 TOE-IN ADJUSTMENT.......................................................................................................254 REAR AXLE HOUSING...........................................................................................................259 REAR AXLE HOUSING.......................................................................................................259 Removal.............................................................................................................259 Installation........................................................................................................259 WHEEL MOTOR.............................................................................................................259 Removal.............................................................................................................259 Cleaning and Inspection.............................................................................................260 Installation........................................................................................................260 Maximum Cap Screw Usage.............................................................................................260 SECTION H - HYDRAIR SUSPENSIONS.....................................................................................................261 HYDRAIR II SUSPENSIONS INDEX....................................................................................................261 FRONT SUSPENSION............................................................................................................263 REAR SUSPENSION.............................................................................................................271 OILING AND CHARGING PROCEDURE...............................................................................................275 GENERAL.................................................................................................................275 EQUIPMENT LIST..........................................................................................................275 HYDRAIR® CHARGING KIT...................................................................................................275 Installation of Charging Kit........................................................................................275 Removal of Charging Kit.............................................................................................276 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS.......................................................................276 FRONT SUSPENSION........................................................................................................277 Front Suspension Oiling.............................................................................................277 Front Suspension Nitrogen Charging..................................................................................278 REAR SUSPENSION.........................................................................................................279 Rear Suspension Oiling..............................................................................................279 Rear Suspension Nitrogen Charging...................................................................................280 OIL AND NITROGEN SPECIFICATIONS CHART...................................................................................282 SECTION J - BRAKE CIRCUIT...........................................................................................................283 BRAKE CIRCUIT INDEX.............................................................................................................283 CARLISLE WHEEL SPEED DISC BRAKES............................................................................................323 BRAKE CALIPERS..........................................................................................................323 Lining Replacement..................................................................................................323 Brake Caliper Removal...............................................................................................324 Brake Caliper Installation..........................................................................................325 Brake Caliper Disassembly...........................................................................................325 Inspection..........................................................................................................325 Brake Caliper Assembly..............................................................................................326 BRAKE CALIPER BENCH TEST................................................................................................327 BRAKE BLEEDING PROCEDURE................................................................................................327 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.......................................................................328 Front Brake Conditioning............................................................................................328 Temporary Disconnect Procedures For Rear Brakes.....................................................................328 Temporary Disconnect Procedures for Disabling Rear Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks.....329 Temporary Disconnect Procedures for Disabling Rear Brakes For Model 830E HAULPAK® Trucks............................329 SPECIAL TOOLS.......................................................................................................330 ROCKWELL WHEEL SPEED FRONT DISC BRAKES......................................................................................331 BRAKE CALIPER...........................................................................................................331 Removal.............................................................................................................331 Installation........................................................................................................332 Piston Removal......................................................................................................333 Installation........................................................................................................333 Caliper Cleaning and Inspection.....................................................................................333 BRAKE LINING............................................................................................................335 Replacement.........................................................................................................335 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE...........................................................................336 Front Brake Conditioning................................................................................................336 Temporary Disconnect Procedures For Rear Brakes.........................................................................336 BRAKE BLEEDING PROCEDURES...............................................................................................338 CARLISLE ARMATURE SPEED REAR DISC BRAKES....................................................................................339 BRAKE CALIPERS..........................................................................................................339 Lining Replacement..................................................................................................339 Caliper Removal.....................................................................................................340 Inspection..........................................................................................................342 Installation........................................................................................................343 Disassembly of Brake Calipers.......................................................................................344 Inspection..........................................................................................................346 Caliper Assembly....................................................................................................346 BRAKE CALIPER BENCH TEST................................................................................................347 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.......................................................................348 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE...............................................................................348 General.................................................................................................................348 Carlisle Armature Speed Disc Brakes Conditioning (Burnishing) Rear Brakes...............................................348 BLEEDING PROCEDURE......................................................................................................349 TEMPORARY DISCONNECT PROCEDURES FOR DISABLING FRONT BRAKES..............................................................349 Temporary Disconnect Procedures for Disabling Front Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks....350 Temporary Disconnect Procedures for Disabling Front Brakes For Model 830E HAULPAK® Trucks...........................350 ROCKWELL ARMATURE SPEED REAR DISC BRAKES....................................................................................351 REAR BRAKES.............................................................................................................351 CALIPER, DISC, AND PARKING BRAKE........................................................................................351 Caliper, Disc, And Parking Brake Removal............................................................................351 Caliper, Disc, And Parking Brake Installation.......................................................................352 CALIPER, DISC, AND PARKING BRAKE REMOVAL................................................................................354 Caliper, Disc, And Parking Brake Installation.......................................................................355 CALIPER PISTON ASSEMBLY.................................................................................................356 Piston Assembly Removal.............................................................................................356 Piston Assembly Inspection..........................................................................................356 Piston Assembly Installation........................................................................................356 FUNCTIONAL TEST OF PISTON ASSEMBLY......................................................................................357 Return Spring Force.................................................................................................357 Built-In Clearance..................................................................................................357 Grip Force..........................................................................................................358 Grip Force Measurement..............................................................................................359 Spring Force Measurement............................................................................................360 Disassembly of Piston Assembly......................................................................................361 Assembly of Piston Assembly.........................................................................................362 BENCH TEST..............................................................................................................362 BRAKE LINING............................................................................................................363 Replacement.........................................................................................................363 Brake Pad Conditioning (Burnishing) Procedure.......................................................................365 General.............................................................................................................365 Conditioning (Burnishing) Rear Brakes...............................................................................365 BLEEDING PROCEDURE......................................................................................................366 Temporary Disconnect Procedures for Disabling Front Brakes..........................................................366 TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Models 630E and 685E Komatsu Trucks......................367 TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Model 830E Komatsu Trucks................................367 ROCKWELL DISC PARKING BRAKE.................................................................................................369 CALIPER STYLE IDENTIFICATION............................................................................................369 PARK BRAKE CALIPER......................................................................................................370 Park Brake Caliper Removal..........................................................................................370 Park Brake Caliper Installation.....................................................................................370 Parking Brake Adjustment (SCL70)....................................................................................370 Parking Brake Adjustment (SCL15)....................................................................................372 Park Brake Caliper Disassembly......................................................................................373 Cleaning and Inspection.............................................................................................374 Park Brake Caliper Assembly.........................................................................................375 PARK BRAKE LINING REPLACEMENT...........................................................................................375 PARK BRAKE BURNISH PROCEDURE............................................................................................375 Lining Conditioning.................................................................................................375 BRAKE BLEEDING PROCEDURE................................................................................................375 CARLISLE DISC PARKING BRAKE.................................................................................................377 PARKING BRAKE OPERATION.................................................................................................377 TRUCKS WITH ROCKWELL SERVICE BRAKES.....................................................................................377 Caliper Removal.....................................................................................................377 Caliper Installation................................................................................................378 TRUCKS WITH CARLISLE SERVICE BRAKES.....................................................................................379 Caliper Removal.....................................................................................................379 Caliper Installation................................................................................................379 Lining Replacement..................................................................................................380 Caliper Disassembly.................................................................................................380 Inspection..........................................................................................................380 Caliper Assembly....................................................................................................381 BRAKE CALIPER BENCH TEST................................................................................................382 PARKING BRAKE BLEEDING..................................................................................................382 CONDITIONING PROCEDURE FOR DISC PARKING BRAKE...........................................................................382 500 HOUR SERVICE GUIDE FOR DISC PARKING BRAKE...........................................................................383 SECTION K - AIR SYSTEM..............................................................................................................385 AIR SYSTEM INDEX................................................................................................................385 AIR SYSTEM OPERATION........................................................................................................385 AIR SYSTEM COMPONENT REPAIR.................................................................................................385 AIR STARTER CIRCUIT (If Equipped)...........................................................................................385 SECTION L - HYDRAULIC SYSTEM........................................................................................................403 HYDRAULIC SYSTEM INDEX..........................................................................................................403 HYDRAULIC CHECK-OUT PROCEDURE...............................................................................................505 STEERING AND BRAKE PUMP.................................................................................................505 Pressure Check And Adjustment Procedure.............................................................................505 BLEEDDOWN MANIFOLD......................................................................................................506 SHOCK & SUCTION VALVES..................................................................................................507 Shock & Suction Valve Settings......................................................................................507 LEAKAGE TESTS...........................................................................................................507 Steering Control Unit & Flow Amplifier..............................................................................508 Bleed Down Manifold.................................................................................................509 TROUBLESHOOTING CHART...................................................................................................510 TROUBLESHOOTING CHART...................................................................................................513 TROUBLESHOOTING CHART...................................................................................................516 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE.............................................................................518 HYDRAULIC SYSTEM FLUSHING PROCEDURE.........................................................................................521 SECTION M - OPTIONS AND SPECIAL TOOLS...............................................................................................523 OPTIONS AND SPECIAL TOOLS INDEX.................................................................................................523 FIRE CONTROL SYSTEM (MANUAL)................................................................................................527 Operation...............................................................................................................527 Inspection and Maintenance..............................................................................................527 Recharging Procedures...................................................................................................528 ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM.........................................................................529 SYSTEM ADJUSTMENT.......................................................................................................529 PUMP....................................................................................................................529 Removal.............................................................................................................529 Disassembly.........................................................................................................529 Inspection..........................................................................................................531 Assembly............................................................................................................531 Installation........................................................................................................532 BLOWER DRIVE MOTOR......................................................................................................532 Removal.............................................................................................................533 Disassembly.........................................................................................................533 Inspection Of Parts.................................................................................................534 Assembly............................................................................................................534 Installation........................................................................................................535 BLOWER BEARING REPAIR...................................................................................................535 Removal.............................................................................................................535 Replacement.........................................................................................................535 Assembly............................................................................................................536 AIR CLEANER.............................................................................................................536 Assembly............................................................................................................536 Removal.............................................................................................................536 Washing Air Cleaner.................................................................................................536 Assembly............................................................................................................536 WIGGINS QUICK FILL FUEL SYSTEM..............................................................................................537 FUEL RECEIVER...........................................................................................................537 TANK BREATHER VALVE.....................................................................................................538 Removal.............................................................................................................538 Installation........................................................................................................538 Disassembly.........................................................................................................538 Assembly............................................................................................................538 LEFT SIDE FILL..........................................................................................................539 BUCKEYE QUICK FUEL SYSTEM...................................................................................................541 FUEL TANK BREATHER VALVE................................................................................................541 Maintenance.........................................................................................................541 Filter Service......................................................................................................541 Disassembly.........................................................................................................541 Inspection..........................................................................................................541 Assembly............................................................................................................541 FUEL RECEIVER...........................................................................................................542 FAN DRIVE CLUTCH............................................................................................................543 GENERAL DESCRIPTION.....................................................................................................543 COMPONENTS..............................................................................................................543 Input...............................................................................................................543 Output..............................................................................................................544 Stationary Components...............................................................................................544 OPERATION MODES.........................................................................................................544 Fully Engaged.......................................................................................................544 Modulated Variable Speed............................................................................................545 Fully Released......................................................................................................545 Remember:...........................................................................................................545 Lubricating & Cooling Oil...........................................................................................545 MAINTENANCE.............................................................................................................546 Maintenance Checks To Be Made.......................................................................................546 TROUBLE SHOOTING........................................................................................................548 Basic Preliminary Checks............................................................................................548 FIELD CHECK DIAGNOSIS...................................................................................................549 Preliminary Checks With Engine Off..................................................................................549 Check Clutch Release................................................................................................549 Check Clutch Lock-up................................................................................................549 Overheating Complaint...............................................................................................550 Thermal Sensor And Solenoid Valve...................................................................................550 On Truck Test.......................................................................................................550 Off Truck Test......................................................................................................551 Test Conditions and Requirements:...................................................................................551 TEST:...................................................................................................................551 TROUBLESHOOTING CHART...................................................................................................553 PROBABLE CAUSES.....................................................................................................553 SUGGESTED CORRECTIVE ACTIONS........................................................................................553 PROBABLE CAUSES.....................................................................................................554 SUGGESTED CORRECTIVE ACTIONS........................................................................................554 PROBABLE CAUSES.....................................................................................................555 SUGGESTED CORRECTIVE ACTIONS........................................................................................555 FAN CLUTCH DISASSEMBLY INSTRUCTIONS.....................................................................................557 REASSEMBLY OF THE FAN CLUTCH............................................................................................564 INSPECTION OF PARTS.....................................................................................................575 REBUILD TOOLS...........................................................................................................580 ENGINE COOLANT HEATER.......................................................................................................581 Maintenance.............................................................................................................581 HEATING ELEMENT.........................................................................................................581 Removal.............................................................................................................581 Installation........................................................................................................581 THERMOSTAT..............................................................................................................582 Removal.............................................................................................................582 Installation........................................................................................................582 SPECIAL TOOLS...............................................................................................................585 AIR CONDITIONING SYSTEM.....................................................................................................591 Environmental Impact....................................................................................................591 OPERATOR CAB AIR CONDITIONING...........................................................................................592 PRINCIPLES OF REFRIGERATION.............................................................................................592 Air Conditioning....................................................................................................592 Refrigeration - The Act Of Cooling..................................................................................593 The Refrigeration Cycle.............................................................................................593 AIR CONDITIONER SYSTEM COMPONENTS.......................................................................................594 Compressor (Refrigerant Pump).......................................................................................594 Service Valves......................................................................................................594 Condenser...........................................................................................................594 Expansion Block Valve...............................................................................................595 Evaporator..........................................................................................................595 ELECTRICAL CIRCUIT......................................................................................................596 Thermostat..........................................................................................................596 Compressor Clutch...................................................................................................596 Trinary™ Switch.....................................................................................................597 SYSTEM SERVICING........................................................................................................598 SYSTEM OIL..............................................................................................................599 Handling and Reusing PAG Oil........................................................................................599 Oil Quantity........................................................................................................599 Replacing Oil After Servicing the System............................................................................599 Setting Up a New Compressor.........................................................................................599 REFRIGERANT.............................................................................................................600 Recycled Refrigerant................................................................................................600 Reclaimed Refrigerant...............................................................................................600 Refrigerant Quantity................................................................................................600 R-134a Refrigerant Containers.......................................................................................600 SERVICE TOOLS AND EQUIPMENT.............................................................................................601 Recovery/Recycle Station............................................................................................601 Leak Detector.......................................................................................................601 Service Valves......................................................................................................602 Vacuum Pump.........................................................................................................602 Manifold Gauge Set..................................................................................................603 Installing Manifold Gauge Set.......................................................................................604 Purging Air From Service Hoses......................................................................................605 Stabilizing the AC System...........................................................................................606 SYSTEM PERFORMANCE TEST.................................................................................................606 SYSTEM LEAK TESTING.....................................................................................................607 Electronic leak detector............................................................................................607 Tracer dyes.........................................................................................................607 Soap and water......................................................................................................607 SYSTEM REPAIR...........................................................................................................608 System Cleaning.....................................................................................................608 Hoses and Fittings..................................................................................................608 Lines...............................................................................................................608 Expansion Valve.....................................................................................................608 Receiver-Drier......................................................................................................609 Thermostat..........................................................................................................609 Compressor..........................................................................................................609 Clutch..............................................................................................................609 Servicing the Compressor Clutch.....................................................................................610 Pulley Removal......................................................................................................612 Clutch Coil Check...................................................................................................612 Pulley Installation.................................................................................................612 Clutch Assembly Installation........................................................................................613 RECOVERING AND RECYCLING THE REFRIGERANT................................................................................614 Performing the Recovery Cycle.......................................................................................614 Performing the Recycling Procedure..................................................................................614 Evacuating and Charging the AC System...............................................................................614 EVACUATING THE SYSTEM...................................................................................................615 CHARGING THE AC SYSTEM..................................................................................................616 TROUBLESHOOTING.........................................................................................................617 Pre-Diagnosis Checks................................................................................................617 Preparing For Diagnosis.............................................................................................617 Preliminary Steps...................................................................................................617 System Performance Test.............................................................................................617 Diagnosis Of Gauge Readings And System Performance..................................................................618 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM.........................................................................625 AFTERCOOLER OPERATION AND REPAIR............................................................................................631 OPERATION...............................................................................................................631 MAINTENANCE.............................................................................................................631 Removal.............................................................................................................631 Installation........................................................................................................631 Disassembly.........................................................................................................632 Cleaning and Inspection.............................................................................................633 Assembly............................................................................................................633 AIR DRYER (AEROFINER III)...................................................................................................635 AIR DRYER...............................................................................................................635 Service.............................................................................................................635 Indications To Change Desiccant.....................................................................................635 Removal.............................................................................................................636 Installation........................................................................................................636 Disassembly.........................................................................................................636 Assembly............................................................................................................637 CHECK VALVE.............................................................................................................637 Removal.............................................................................................................637 Installation........................................................................................................637 PURGE VALVE & HEATER....................................................................................................638 Removal.............................................................................................................638 Inspection..........................................................................................................638 Installation........................................................................................................638 24VDC ELECTRIC SUPPLY SYSTEM................................................................................................651 ELECTRICAL SYSTEM DESCRIPTION...........................................................................................651 BATTERY.................................................................................................................651 Maintenance and Service.............................................................................................651 Troubleshooting.....................................................................................................651 BATTERY CHARGING SYSTEM (Niehoff).......................................................................................653 General Description.................................................................................................653 TROUBLESHOOTING PROCEDURES (On- Truck)..................................................................................653 Equipment Required:.................................................................................................653 Preliminary Checks..................................................................................................654 Test Setup..........................................................................................................654 Test Procedure......................................................................................................654 Regulator Bypass Test...............................................................................................655 ON VEHICLE TROUBLESHOOTING GUIDE........................................................................................657 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage..........................................657 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:....................................................................657 CHARGE VOLT AND AMP VALUES..........................................................................................658 DEFINITIONS.........................................................................................................658 ADVANCED SYSTEM TROUBLESHOOTING.........................................................................................659 Static Test - Engine OFF, Key ON, Battery Switch ON.................................................................659 Go To Alternator....................................................................................................659 Go To Regulator (If Required).......................................................................................660 Go To Regulator Connector On The Alternator.........................................................................660 NIEHOFF Alternator Overhaul Manual..........................................................................................661 TABLE OF CONTENTS.......................................................................................................661 ALTERNATOR SPECIFICATIONS...........................................................................................663 ON-VEHICLE TEST.....................................................................................................666 Equipment:......................................................................................................666 Preliminary Checks:.............................................................................................666 Test Set-up.....................................................................................................666 Test Procedure..................................................................................................666 ON-VEHICLE TEST.....................................................................................................667 Bypass Test:....................................................................................................667 BENCH TEST..........................................................................................................668 Equipment:......................................................................................................668 TEST 1 - NO-LOAD TEST...............................................................................................668 TEST 2 - FULL LOAD TEST.............................................................................................668 TEST 3 - REGULATOR BYPASS TEST......................................................................................668 STATIC TESTS........................................................................................................669 EQUIPMENT:..........................................................................................................669 REGULATOR TESTS.....................................................................................................669 TEST 1 - Check For Shorted Output Transistor........................................................................669 TEST 2 - Check Function Of Clamping Diode...........................................................................669 FIELD COIL TESTS....................................................................................................669 TEST 3 - Check For Open Field Coil..................................................................................669 TEST 4 - Check For Grounded Field Coil..............................................................................670 CONTROL BOX TESTS...................................................................................................670 TEST 5 - Check Continuity Of Terminal Strip Connections.............................................................670 TEST 6 - Diode Heat Sink Tests......................................................................................670 TEST 7 - Check Positive Diodes......................................................................................671 TEST 8 - Check Negative Diodes......................................................................................671 TEST 9 - Check Front & Rear Stator..................................................................................671 ALTERNATOR DISASSEMBLY..............................................................................................672 FAN REMOVAL.....................................................................................................672 PULLEY REMOVAL..................................................................................................672 REGULATOR REMOVAL...............................................................................................672 END HOUSING REMOVAL.............................................................................................673 REAR ROTOR REMOVAL..............................................................................................673 Alternate Method............................................................................................673 REAR BEARING REMOVAL............................................................................................673 FRONT HOUSING REMOVAL...........................................................................................674 CONTROL UNIT ASSEMBLY REMOVAL...................................................................................675 FRONT BEARING REMOVAL...........................................................................................676 FRONT ROTOR REMOVAL.............................................................................................676 Alternate Method............................................................................................676 FIELD COIL REMOVAL..............................................................................................676 ALTERNATOR ASSEMBLY.............................................................................................677 FIELD COIL ASSEMBLY.............................................................................................677 FRONT BEARING ASSEMBLY..........................................................................................678 FRONT ROTOR ASSEMBLY............................................................................................679 FRONT HOUSING - STATOR, FIELD COIL & SHELL ASSEMBLY.............................................................680 REAR ROTOR ASSEMBLY.............................................................................................682 CONTROL UNIT ASSEMBLY REPLACEMENT...............................................................................681 END HOUSING ASSEMBLY............................................................................................682 REAR BEARING ASSEMBLY...........................................................................................684 PRESS FIT REAR BEARINGS.........................................................................................684 LOOSE FIT REAR BEARINGS.........................................................................................684 REGULATOR ASSEMBLY..............................................................................................684 FAN ASSEMBLY....................................................................................................685 PULLEY ASSEMBLY.................................................................................................685 BF4822 STATOR SERVICE TOOL INSTRUCTIONS.............................................................................686 Function of Service Tool........................................................................................686 STATOR REMOVAL AND REPLACEMENT..................................................................................686 Pressure Plate Set-up (Refer to Figure 13-42)...............................................................686 STATOR INSTALLATION (Refer to Figure 13-41).....................................................................687 PRESSURE PLATE SET UP (Refer to Figure 13- 42)..................................................................688 OPTIONAL OPERATOR SEAT......................................................................................................689 SEAT....................................................................................................................689 Removal.............................................................................................................689 Installation........................................................................................................689 Disassembly.........................................................................................................690 Assembly............................................................................................................692 Air Suspension Cam Adjustment.......................................................................................693 SEAT MAINTENANCE AND REPAIR.............................................................................................694 Headrest............................................................................................................694 Backrest............................................................................................................694 Armrests............................................................................................................694 Seat Cushion........................................................................................................694 Seat Frame..........................................................................................................694 Slides..............................................................................................................695 Suspension..........................................................................................................695 TDI SINGLE STAGE AIR STARTER................................................................................................697 STARTER.................................................................................................................697 Removal.............................................................................................................697 Installation........................................................................................................697 Disassembly.........................................................................................................697 Cleaning............................................................................................................701 Parts Inspection....................................................................................................701 PARTS INSPECTION (Refer to Figure 15-2 for reference to parts)..........................................................702 Assembly............................................................................................................704 AUTOMATIC TRIP VALVE....................................................................................................708 Disassembly.........................................................................................................708 Reassembly..........................................................................................................708 Operation Check.....................................................................................................709 TDI TWO-STAGE AIR STARTER...................................................................................................711 AIR STARTER.............................................................................................................711 Removal.............................................................................................................711 Installation........................................................................................................711 Description of Basic Groups.........................................................................................711 Disassembly.........................................................................................................714 Cleaning and Inspection.............................................................................................716 Assembly............................................................................................................718 TDI TWO-STAGE AIR STARTER TROUBLESHOOTING GUIDE.........................................................................724 M15001 - TDI AIR STARTER TABLE OF CONTENTS..............................................................................725 INGERSOLL-RAND TURBINE POWERED STARTER......................................................................................727 MAINTENANCE.............................................................................................................727 Removal.............................................................................................................727 Installation........................................................................................................727 Disassembly Tips....................................................................................................727 Disassembly - Housing Exhaust Cover, Motor Assembly, and Motor Housing..............................................730 Disassembly - Drive Housing.........................................................................................732 Assembly Tips.......................................................................................................734 Lubrication.........................................................................................................734 Assembly - Gear Case and Drive Housing..............................................................................735 Assembly - Intermediate Gear Case, Motor Housing, Motor Assembly, and Housing Exhaust Cover.........................736 TEST AND INSPECTION PROCEDURE...........................................................................................741 TROUBLESHOOTING CHART...................................................................................................742 24 VDC ELECTRIC START SYSTEM................................................................................................755 OPERATION...............................................................................................................755 CRANKING MOTOR..........................................................................................................755 Removal.............................................................................................................755 Installation........................................................................................................755 CRANKING MOTOR TROUBLESHOOTING..........................................................................................756 Preliminary Inspection..............................................................................................756 No-Load Test........................................................................................................756 Interpreting Results of Tests.......................................................................................756 Disassembly.........................................................................................................757 Cleaning and Inspection.............................................................................................757 Armature Servicing..................................................................................................757 Field Coil Checks...................................................................................................758 Field Coil Removal..................................................................................................758 Solenoid Checks.....................................................................................................760 Test................................................................................................................760 Assembly............................................................................................................761 Pinion Clearance....................................................................................................761 Magnetic Switch.....................................................................................................762 Removal.............................................................................................................762 Installation........................................................................................................762 Coil Test...........................................................................................................762 ELECTRIC START SYSTEM WIRING DIAGRAMS...................................................................................763 SECTION N - OPERATOR'S CAB..........................................................................................................803 OPERATOR'S CAB INDEX............................................................................................................803 CAB COMPONENTS..............................................................................................................811 WINDSHIELD WIPER........................................................................................................811 Removal.............................................................................................................811 Installation........................................................................................................811 WINDSHIELD WASHER.......................................................................................................812 Operation...........................................................................................................812 Service.............................................................................................................812 SECTION P - LUBRICATION AND SERVICE.................................................................................................837 LUBRICATION AND SERVICE INDEX...................................................................................................837 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................................................863 AXLE BOX................................................................................................................863 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................................................864 ARMATURE AREA...........................................................................................................864 AT TIRE CHANGE - FOR ALL MOTORIZED WHEELS...............................................................................864 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................................................865 GENERATOR / ALTERNATOR..................................................................................................865 GRID BLOWER MOTOR.......................................................................................................865 CONTROL EQUIPMENT CHECKS................................................................................................865 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................................................866 AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM..........................................................................866 VEHICLE OPERATIONS TESTS................................................................................................866 SECTION Q - ALPHABETICAL INDEX......................................................................................................867 SECTION R - SYSTEM SCHEMATICS.......................................................................................................871 SYSTEM SCHEMATICS INDEX.........................................................................................................871
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