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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX:AFE32-AS – AFE32-DH AFE32-DN – AFE32 DR®) KOMATSU 830E – PDF Download
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- KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL SUFFIX:AFE32-AS – AFE32-DH AFE32-DN – AFE32 DR®
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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX:AFE32-AS – AFE32-DH AFE32-DN – AFE32 DR®) KOMATSU 830E
KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX:AFE32-AS – AFE32-DH AFE32-DN – AFE32 DR®) KOMATSU 830E – PDF DOWNLOAD:
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KOMATSU 830E DUMP TRUCK SERVICE REPAIR MANUAL (SERIAL SUFFIX:AFE32-AS – AFE32-DH AFE32-DN – AFE32 DR®) 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-AS – AFE32-DH AFE32-DN – AFE32 DR®) KOMATSU 830E
COVER........................................................................................................................... 1 FOREWARD........................................................................................................................ 3 TABLE OF CONTENTS............................................................................................................... 5 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 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 STRUCTURES...................................................................................................................... 53 DUMP BODY................................................................................................................... 59 Removal................................................................................................................. 59 Installation............................................................................................................ 60 BODY PADS............................................................................................................... 60 Adjustment.......................................................................................................... 61 BODY GUIDE.............................................................................................................. 61 BODY LOCK PIN........................................................................................................... 61 BODY POSITION INDICATOR................................................................................................. 61 ROCK EJECTORS........................................................................................................... 62 Inspection.......................................................................................................... 62 ENGINE, FUEL, COOLING AND AIR COOLER............................................................................................ 63 AIR FILTRATION SYSTEM....................................................................................................... 87 AIR CLEANER............................................................................................................. 87 Operation........................................................................................................... 87 General Service Information......................................................................................... 87 MAIN FILTER ELEMENT..................................................................................................... 87 Removal............................................................................................................. 87 Installation........................................................................................................ 88 SAFETY FILTER ELEMENT................................................................................................... 89 Removal............................................................................................................. 89 Installation........................................................................................................ 89 AIR INTAKE TROUBLESHOOTING.............................................................................................. 89 AIR CLEANER ASSEMBLY CLEANING........................................................................................... 89 Main Filter Cleaning................................................................................................ 89 Precleaner Section Cleaning......................................................................................... 90 ELECTRICAL SYSTEM (24VDC NON-PROPULSION)........................................................................................ 93 24 VDC ELECTRIC SUPPLY SYSTEM............................................................................................... 95 ELECTRICAL SYSTEM DESCRIPTION........................................................................................... 95 BATTERY................................................................................................................. 95 Maintenance and Service............................................................................................. 95 Troubleshooting..................................................................................................... 95 BATTERY CHARGING SYSTEM (Used with DDC and Cummins Engines)............................................................. 96 General Description................................................................................................. 96 Operating Principles................................................................................................ 97 Energizing Speed.................................................................................................... 98 Rated Voltage....................................................................................................... 98 Magnetizing The Rotor............................................................................................... 98 INTEGRAL CHARGING SYSTEM (Battery Charging Alternator).................................................................. 99 Troubleshooting Procedures.......................................................................................... 99 Integral Charging System Repair..................................................................................... 99 Regulator Check.....................................................................................................100 Rectifier Bridge Check (Omit for Overcharged Battery)...............................................................100 Field Coil Checks...................................................................................................100 Diode Trio Check....................................................................................................101 Stator Checks (Omit for Overcharged Battery)........................................................................101 Disassembly (Refer to Figure 2-10)..................................................................................101 Reassembly..........................................................................................................102 DDEC II ELECTRONIC ENGINE CONTROL...........................................................................................111 GENERAL DESCRIPTION.....................................................................................................111 COMPONENT DESCRIPTION...................................................................................................112 Electronic Control Module...........................................................................................112 Electronic Unit Injectors...........................................................................................112 System Sensors and Operator inputs..................................................................................113 ENGINE PROTECTION SYSTEM................................................................................................114 DIAGNOSTICS.............................................................................................................114 BATTERY EQUALIZER.......................................................................................................116 Troubleshooting.....................................................................................................116 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 DRIVE AXLE, SPINDLE AND WHEELS..................................................................................................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 REAR AXLE HOUSING...........................................................................................................263 REAR AXLE HOUSING.......................................................................................................263 Removal.............................................................................................................263 Installation........................................................................................................263 WHEEL MOTOR.............................................................................................................263 Removal.............................................................................................................263 Cleaning and Inspection.............................................................................................264 Installation........................................................................................................264 Maximum Cap Screw Usage.............................................................................................264 HYDRAIR II SUSPENSIONS..........................................................................................................265 OILING AND CHARGING PROCEDURE...............................................................................................279 GENERAL.................................................................................................................279 EQUIPMENT LIST..........................................................................................................279 HYDRAIR® CHARGING KIT...................................................................................................279 Installation of Charging Kit........................................................................................279 Removal of Charging Kit.............................................................................................280 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS.......................................................................280 FRONT SUSPENSION........................................................................................................281 Front Suspension Oiling.............................................................................................281 Front Suspension Nitrogen Charging..................................................................................282 REAR SUSPENSION.........................................................................................................283 Rear Suspension Oiling..............................................................................................283 Rear Suspension Nitrogen Charging...................................................................................284 OIL AND NITROGEN SPECIFICATIONS CHART.......................................................................................286 BRAKE CIRCUIT...................................................................................................................287 CARLISLE WHEEL SPEED DISC BRAKES............................................................................................327 BRAKE CALIPERS..........................................................................................................327 Lining Replacement..................................................................................................327 Brake Caliper Removal...............................................................................................328 Brake Caliper Installation..........................................................................................329 Brake Caliper Disassembly...........................................................................................329 Inspection..........................................................................................................329 Brake Caliper Assembly..............................................................................................330 BRAKE CALIPER BENCH TEST................................................................................................331 BRAKE BLEEDING PROCEDURE................................................................................................331 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE...........................................................................332 Front Brake Conditioning................................................................................................332 Temporary Disconnect Procedures For Rear Brakes.........................................................................332 Temporary Disconnect Procedures for Disabling Rear Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks.....333 Temporary Disconnect Procedures for Disabling Rear Brakes For Model 830E HAULPAK® Trucks............................333 SPECIAL TOOLS...........................................................................................................334 ROCKWELL WHEEL SPEED FRONT DISC BRAKES......................................................................................335 BRAKE CALIPER...........................................................................................................335 Removal.............................................................................................................335 Installation........................................................................................................336 Piston Removal......................................................................................................337 Installation........................................................................................................337 Caliper Cleaning and Inspection.....................................................................................337 BRAKE LINING............................................................................................................339 Replacement.........................................................................................................339 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE...........................................................................340 Front Brake Conditioning................................................................................................340 Temporary Disconnect Procedures For Rear Brakes.........................................................................340 BRAKE BLEEDING PROCEDURES...............................................................................................342 CARLISLE ARMATURE SPEED REAR DISC BRAKES....................................................................................343 BRAKE CALIPERS..........................................................................................................343 Lining Replacement..................................................................................................343 Caliper Removal.....................................................................................................344 Inspection..........................................................................................................346 Installation........................................................................................................347 Disassembly of Brake Calipers.......................................................................................348 Inspection..........................................................................................................350 Caliper Assembly....................................................................................................350 BRAKE CALIPER BENCH TEST................................................................................................351 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE...........................................................................352 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE...........................................................................352 General.............................................................................................................352 Carlisle Armature Speed Disc Brakes Conditioning (Burnishing) Rear Brakes...........................................352 BLEEDING PROCEDURE......................................................................................................353 TEMPORARY DISCONNECT PROCEDURES FOR DISABLING FRONT BRAKES..............................................................353 Temporary Disconnect Procedures for Disabling Front Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks....354 Temporary Disconnect Procedures for Disabling Front Brakes For Model 830E HAULPAK® Trucks...........................354 ROCKWELL ARMATURE SPEED REAR DISC BRAKES....................................................................................355 REAR BRAKES.............................................................................................................355 CALIPER, DISC, AND PARKING BRAKE........................................................................................355 Caliper, Disc, And Parking Brake Removal............................................................................355 Caliper, Disc, And Parking Brake Installation.......................................................................356 CALIPER, DISC, AND PARKING BRAKE REMOVAL............................................................................358 Caliper, Disc, And Parking Brake Installation.......................................................................359 CALIPER PISTON ASSEMBLY.................................................................................................360 Piston Assembly Removal.............................................................................................360 Piston Assembly Inspection..........................................................................................360 Piston Assembly Installation........................................................................................360 FUNCTIONAL TEST OF PISTON ASSEMBLY......................................................................................361 Return Spring Force.................................................................................................361 Built-In Clearance..................................................................................................361 Grip Force..........................................................................................................362 Grip Force Measurement..............................................................................................363 Spring Force Measurement............................................................................................364 Disassembly of Piston Assembly......................................................................................365 Assembly of Piston Assembly.........................................................................................366 BENCH TEST..............................................................................................................366 BRAKE LINING............................................................................................................367 Replacement.........................................................................................................367 Brake Pad Conditioning (Burnishing) Procedure...........................................................................369 General.............................................................................................................369 Conditioning (Burnishing) Rear Brakes...............................................................................369 BLEEDING PROCEDURE......................................................................................................370 Temporary Disconnect Procedures for Disabling Front Brakes..............................................................370 TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Models 630E and 685E Komatsu Trucks..................371 TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Model 830E Komatsu Trucks............................371 ROCKWELL DISC PARKING BRAKE.................................................................................................373 CALIPER STYLE IDENTIFICATION............................................................................................373 PARK BRAKE CALIPER......................................................................................................374 Park Brake Caliper Removal..........................................................................................374 Park Brake Caliper Installation.....................................................................................374 Parking Brake Adjustment (SCL70)....................................................................................374 Parking Brake Adjustment (SCL15)....................................................................................376 Park Brake Caliper Disassembly......................................................................................377 Cleaning and Inspection.............................................................................................378 Park Brake Caliper Assembly.........................................................................................379 PARK BRAKE LINING REPLACEMENT...........................................................................................379 PARK BRAKE BURNISH PROCEDURE............................................................................................379 Lining Conditioning.................................................................................................379 BRAKE BLEEDING PROCEDURE................................................................................................379 CARLISLE DISC PARKING BRAKE.................................................................................................381 PARKING BRAKE OPERATION.................................................................................................381 TRUCKS WITH ROCKWELL SERVICE BRAKES.....................................................................................381 Caliper Removal.....................................................................................................381 Caliper Installation................................................................................................382 TRUCKS WITH CARLISLE SERVICE BRAKES.....................................................................................383 Caliper Removal.....................................................................................................383 Caliper Installation................................................................................................383 Lining Replacement..................................................................................................384 Caliper Disassembly.................................................................................................384 Inspection..........................................................................................................384 Caliper Assembly....................................................................................................385 BRAKE CALIPER BENCH TEST................................................................................................386 PARKING BRAKE BLEEDING..................................................................................................386 CONDITIONING PROCEDURE FOR DISC PARKING BRAKE...........................................................................386 500 HOUR SERVICE GUIDE FOR DISC PARKING BRAKE...........................................................................387 AIR SYSTEM......................................................................................................................389 AIR SYSTEM OPERATION........................................................................................................391 HYDRAUILIC SYSTEM...............................................................................................................407 HYDRAULIC CHECK-OUT PROCEDURE...............................................................................................509 STEERING AND BRAKE PUMP.................................................................................................509 Pressure Check And Adjustment Procedure.............................................................................509 BLEEDDOWN MANIFOLD......................................................................................................510 SHOCK & SUCTION VALVES..................................................................................................511 Shock & Suction Valve Settings......................................................................................511 LEAKAGE TESTS...........................................................................................................511 Steering Control Unit & Flow Amplifier..............................................................................512 Bleed Down Manifold.................................................................................................513 TROUBLESHOOTING CHART.......................................................................................................514 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE.................................................................................522 HYDRAULIC SYSTEM FLUSHING PROCEDURE.........................................................................................525 OPTIONS AND SPECIAL TOOLS.......................................................................................................527 FIRE CONTROL SYSTEM (MANUAL)................................................................................................531 Operation...............................................................................................................531 Inspection and Maintenance..............................................................................................531 Recharging Procedures...................................................................................................532 ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM.........................................................................533 SYSTEM ADJUSTMENT.......................................................................................................533 PUMP....................................................................................................................533 Removal.................................................................................................................533 Disassembly.............................................................................................................533 Inspection..............................................................................................................535 Assembly................................................................................................................535 Installation............................................................................................................536 BLOWER DRIVE MOTOR......................................................................................................536 Removal.................................................................................................................537 Disassembly.............................................................................................................537 Inspection Of Parts.....................................................................................................538 Assembly................................................................................................................538 Installation............................................................................................................539 BLOWER BEARING REPAIR...................................................................................................539 Removal.............................................................................................................539 Replacement.........................................................................................................539 Assembly............................................................................................................540 AIR CLEANER.............................................................................................................540 Assembly............................................................................................................540 Removal.............................................................................................................540 Washing Air Cleaner.................................................................................................540 Assembly............................................................................................................540 WIGGINS QUICK FILL FUEL SYSTEM..............................................................................................541 FUEL RECEIVER...........................................................................................................541 TANK BREATHER VALVE.....................................................................................................542 Removal.............................................................................................................542 Installation........................................................................................................542 Disassembly.........................................................................................................542 Assembly............................................................................................................542 LEFT SIDE FILL..........................................................................................................543 BUCKEYE QUICK FUEL SYSTEM...................................................................................................545 FUEL TANK BREATHER VALVE................................................................................................545 Maintenance.........................................................................................................545 Filter Service......................................................................................................545 Disassembly.........................................................................................................545 Inspection..........................................................................................................545 Assembly............................................................................................................545 FUEL RECEIVER...........................................................................................................546 INSPECTION OF PARTS.........................................................................................................547 REBUILD TOOLS...............................................................................................................552 FAN CLUTCH DISASSEMBLY INSTRUCTIONS.........................................................................................553 REASSEMBLY OF THE FAN CLUTCH................................................................................................560 FAN DRIVE CLUTCH............................................................................................................571 GENERAL DESCRIPTION.....................................................................................................571 COMPONENTS..............................................................................................................571 Input...............................................................................................................571 Output..............................................................................................................572 Stationary Components...............................................................................................572 OPERATION MODES.........................................................................................................572 Fully Engaged.......................................................................................................572 Modulated Variable Speed............................................................................................573 Fully Released......................................................................................................573 Remember:...........................................................................................................573 Lubricating & Cooling Oil...........................................................................................573 MAINTENANCE.............................................................................................................574 Maintenance Checks To Be Made.......................................................................................574 TROUBLE SHOOTING........................................................................................................576 Basic Preliminary Checks............................................................................................576 FIELD CHECK DIAGNOSIS...................................................................................................577 Preliminary Checks With Engine Off..................................................................................577 Check Clutch Release................................................................................................577 Check Clutch Lock-up................................................................................................577 Overheating Complaint...............................................................................................578 Thermal Sensor And Solenoid Valve...................................................................................578 On Truck Test.......................................................................................................578 Off Truck Test......................................................................................................579 Test Conditions and Requirements:...................................................................................579 TEST:...............................................................................................................579 TROUBLESHOOTING CHART.......................................................................................................581 PROBABLE CAUSES.........................................................................................................581 SUGGESTED CORRECTIVE ACTIONS............................................................................................581 PROBABLE CAUSES.........................................................................................................582 SUGGESTED CORRECTIVE ACTIONS............................................................................................582 PROBABLE CAUSES.........................................................................................................583 SUGGESTED CORRECTIVE ACTIONS............................................................................................583 ENGINE COOLANT HEATER.......................................................................................................585 Maintenance.............................................................................................................585 HEATING ELEMENT.........................................................................................................585 Removal.................................................................................................................585 Installation............................................................................................................585 THERMOSTAT..............................................................................................................586 Removal.................................................................................................................586 Installation............................................................................................................586 SPECIAL TOOLS...............................................................................................................589 AIR CONDITIONING SYSTEM.....................................................................................................595 Environmental Impact....................................................................................................595 OPERATOR CAB AIR CONDITIONING...........................................................................................596 PRINCIPLES OF REFRIGERATION.............................................................................................596 Air Conditioning....................................................................................................596 Refrigeration - The Act Of Cooling..................................................................................597 The Refrigeration Cycle.............................................................................................597 AIR CONDITIONER SYSTEM COMPONENTS.......................................................................................598 Compressor (Refrigerant Pump).......................................................................................598 Service Valves......................................................................................................598 Condenser...........................................................................................................598 Expansion Block Valve...............................................................................................599 Evaporator..........................................................................................................599 ELECTRICAL CIRCUIT......................................................................................................600 Thermostat..........................................................................................................600 Compressor Clutch...................................................................................................600 Trinary™ Switch.....................................................................................................601 SYSTEM SERVICING........................................................................................................602 SYSTEM OIL..............................................................................................................603 Handling and Reusing PAG Oil........................................................................................603 Oil Quantity........................................................................................................603 Replacing Oil After Servicing the System............................................................................603 Setting Up a New Compressor.........................................................................................603 REFRIGERANT.............................................................................................................604 Recycled Refrigerant................................................................................................604 Reclaimed Refrigerant...............................................................................................604 Refrigerant Quantity................................................................................................604 R-134a Refrigerant Containers.......................................................................................604 SERVICE TOOLS AND EQUIPMENT.............................................................................................605 Recovery/Recycle Station............................................................................................605 Leak Detector.......................................................................................................605 Service Valves......................................................................................................606 Vacuum Pump.........................................................................................................606 Manifold Gauge Set..................................................................................................607 Installing Manifold Gauge Set.......................................................................................608 Purging Air From Service Hoses......................................................................................609 Stabilizing the AC System...........................................................................................610 SYSTEM PERFORMANCE TEST.................................................................................................610 SYSTEM LEAK TESTING.....................................................................................................611 Electronic leak detector............................................................................................611 Tracer dyes.........................................................................................................611 Soap and water......................................................................................................611 SYSTEM REPAIR...........................................................................................................612 System Cleaning.....................................................................................................612 Hoses and Fittings..................................................................................................612 Lines...............................................................................................................612 Expansion Valve.....................................................................................................612 Receiver-Drier......................................................................................................613 Thermostat..........................................................................................................613 Compressor..........................................................................................................613 Clutch..............................................................................................................613 Servicing the Compressor Clutch.....................................................................................614 Pulley Removal......................................................................................................616 Clutch Coil Check...................................................................................................616 Pulley Installation.................................................................................................616 Clutch Assembly Installation........................................................................................617 RECOVERING AND RECYCLING THE REFRIGERANT................................................................................618 Performing the Recovery Cycle.......................................................................................618 Performing the Recycling Procedure..................................................................................618 Evacuating and Charging the AC System...............................................................................618 EVACUATING THE SYSTEM...................................................................................................619 CHARGING THE AC SYSTEM..................................................................................................620 TROUBLESHOOTING.............................................................................................................621 Pre-Diagnosis Checks....................................................................................................621 Preparing For Diagnosis.................................................................................................621 Preliminary Steps.......................................................................................................621 System Performance Test.................................................................................................621 Diagnosis Of Gauge Readings And System Performance......................................................................622 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM.............................................................................629 AFTERCOOLER OPERATION AND REPAIR............................................................................................635 OPERATION...............................................................................................................635 MAINTENANCE.............................................................................................................635 Removal.............................................................................................................635 Installation........................................................................................................635 Disassembly.........................................................................................................636 Cleaning and Inspection.............................................................................................637 Assembly............................................................................................................637 AIR DRYER (AEROFINER III)...................................................................................................639 AIR DRYER...............................................................................................................639 Service.............................................................................................................639 Indications To Change Desiccant.....................................................................................639 Removal.............................................................................................................640 Installation........................................................................................................640 Disassembly.........................................................................................................640 Assembly............................................................................................................641 CHECK VALVE.............................................................................................................641 Removal.............................................................................................................641 Installation........................................................................................................641 PURGE VALVE & HEATER....................................................................................................642 Removal.............................................................................................................642 Inspection..........................................................................................................642 Installation........................................................................................................642 24VDC ELECTRIC SUPPLY SYSTEM................................................................................................655 ELECTRICAL SYSTEM DESCRIPTION...........................................................................................655 BATTERY.................................................................................................................655 Maintenance and Service.............................................................................................655 Troubleshooting.....................................................................................................655 BATTERY CHARGING SYSTEM (Niehoff).......................................................................................657 General Description.................................................................................................657 TROUBLESHOOTING PROCEDURES (On- Truck)..................................................................................657 Equipment Required:.................................................................................................657 Preliminary Checks..................................................................................................658 Test Setup..........................................................................................................658 Test Procedure......................................................................................................658 Regulator Bypass Test...............................................................................................659 ON VEHICLE TROUBLESHOOTING GUIDE............................................................................................661 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage..............................................661 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:........................................................................661 CHARGE VOLT AND AMP VALUES..............................................................................................662 DEFINITIONS.............................................................................................................662 ADVANCED SYSTEM TROUBLESHOOTING.............................................................................................663 Static Test - Engine OFF, Key ON, Battery Switch ON.....................................................................663 Go To Alternator........................................................................................................663 Go To Regulator (If Required)...........................................................................................664 Go To Regulator Connector On The Alternator.............................................................................664 NIEHOFF Alternator Overhaul Manual..........................................................................................665 TABLE OF CONTENTS.......................................................................................................665 ALTERNATOR SPECIFICATIONS...........................................................................................667 ON-VEHICLE TEST.....................................................................................................670 Equipment:......................................................................................................670 Preliminary Checks:.............................................................................................670 Test Set-up.....................................................................................................670 Test Procedure..................................................................................................670 ON-VEHICLE TEST.....................................................................................................671 Bypass Test:....................................................................................................671 BENCH TEST..........................................................................................................672 Equipment:......................................................................................................672 TEST 1 - NO-LOAD TEST...........................................................................................672 TEST 2 - FULL LOAD TEST.........................................................................................672 TEST 3 - REGULATOR BYPASS TEST..................................................................................672 STATIC TESTS........................................................................................................673 EQUIPMENT:......................................................................................................673 REGULATOR TESTS.................................................................................................673 TEST 1 - Check For Shorted Output Transistor....................................................................673 TEST 2 - Check Function Of Clamping Diode.......................................................................673 FIELD COIL TESTS................................................................................................673 TEST 3 - Check For Open Field Coil..............................................................................673 TEST 4 - Check For Grounded Field Coil..........................................................................674 CONTROL BOX TESTS...............................................................................................674 TEST 5 - Check Continuity Of Terminal Strip Connections.........................................................674 TEST 6 - Diode Heat Sink Tests..................................................................................674 TEST 7 - Check Positive Diodes..................................................................................675 TEST 8 - Check Negative Diodes..................................................................................675 TEST 9 - Check Front & Rear Stator..............................................................................675 ALTERNATOR DISASSEMBLY......................................................................................................676 FAN REMOVAL.............................................................................................................676 PULLEY REMOVAL..........................................................................................................676 REGULATOR REMOVAL.......................................................................................................676 END HOUSING REMOVAL.....................................................................................................677 REAR ROTOR REMOVAL......................................................................................................677 Alternate Method........................................................................................................677 REAR BEARING REMOVAL....................................................................................................677 FRONT HOUSING REMOVAL...................................................................................................678 CONTROL UNIT ASSEMBLY REMOVAL...........................................................................................679 FRONT BEARING REMOVAL...................................................................................................680 FRONT ROTOR REMOVAL.....................................................................................................680 Alternate Method........................................................................................................680 FIELD COIL REMOVAL......................................................................................................680 ALTERNATOR ASSEMBLY.....................................................................................................681 FIELD COIL ASSEMBLY.................................................................................................681 FRONT BEARING ASSEMBLY..............................................................................................682 FRONT ROTOR ASSEMBLY................................................................................................683 FRONT HOUSING - STATOR, FIELD COIL & SHELL ASSEMBLY.................................................................684 CONTROL UNIT ASSEMBLY REPLACEMENT...................................................................................685 REAR ROTOR ASSEMBLY.................................................................................................686 END HOUSING ASSEMBLY................................................................................................686 REAR BEARING ASSEMBLY...............................................................................................688 PRESS FIT REAR BEARINGS.............................................................................................688 LOOSE FIT REAR BEARINGS.............................................................................................688 REGULATOR ASSEMBLY..................................................................................................688 FAN ASSEMBLY........................................................................................................689 PULLEY ASSEMBLY.....................................................................................................689 BF4822 STATOR SERVICE TOOL INSTRUCTIONS.....................................................................................690 Function of Service Tool................................................................................................690 STATOR REMOVAL AND REPLACEMENT..........................................................................................690 Pressure Plate Set-up (Refer to Figure 13-42)...........................................................................690 STATOR INSTALLATION (Refer to Figure 13-41).............................................................................691 PRESSURE PLATE SET UP (Refer to Figure 13- 42)..........................................................................692 OPTIONAL OPERATOR SEAT......................................................................................................693 SEAT....................................................................................................................693 Removal.............................................................................................................693 Installation........................................................................................................693 Disassembly.........................................................................................................694 Assembly............................................................................................................696 Air Suspension Cam Adjustment.......................................................................................697 SEAT MAINTENANCE AND REPAIR.............................................................................................698 Headrest............................................................................................................698 Backrest............................................................................................................698 Armrests............................................................................................................698 Seat Cushion........................................................................................................698 Seat Frame..........................................................................................................698 Slides..............................................................................................................699 Suspension..........................................................................................................699 TDI SINGLE STAGE AIR STARTER................................................................................................701 STARTER.................................................................................................................701 Removal.............................................................................................................701 Installation........................................................................................................701 Disassembly.........................................................................................................701 Cleaning............................................................................................................705 Parts Inspection....................................................................................................705 PARTS INSPECTION (Refer to Figure 15-2 for reference to parts)..........................................................706 Assembly............................................................................................................708 AUTOMATIC TRIP VALVE....................................................................................................712 Disassembly.........................................................................................................712 Reassembly..........................................................................................................712 Operation Check.....................................................................................................713 TDI TWO-STAGE AIR STARTER...................................................................................................715 AIR STARTER.............................................................................................................715 Removal.............................................................................................................715 Installation........................................................................................................715 Description of Basic Groups.........................................................................................715 Disassembly.........................................................................................................718 Cleaning and Inspection.............................................................................................720 Assembly............................................................................................................722 TDI TWO-STAGE AIR STARTER TROUBLESHOOTING GUIDE.............................................................................728 INGERSOLL-RAND TURBINE POWERED STARTER......................................................................................731 MAINTENANCE.............................................................................................................731 Removal.............................................................................................................731 Installation........................................................................................................731 Disassembly Tips....................................................................................................731 Disassembly - Housing Exhaust Cover, Motor Assembly, and Motor Housing..............................................734 Disassembly - Drive Housing.........................................................................................736 Assembly Tips.......................................................................................................738 Lubrication.........................................................................................................738 Assembly - Gear Case and Drive Housing..............................................................................739 Assembly - Intermediate Gear Case, Motor Housing, Motor Assembly, and Housing Exhaust Cover.........................740 TEST AND INSPECTION PROCEDURE...........................................................................................745 TROUBLESHOOTING CHART...................................................................................................746 24 VDC ELECTRIC START SYSTEM................................................................................................759 OPERATION...............................................................................................................759 CRANKING MOTOR..........................................................................................................759 Removal.............................................................................................................759 Installation........................................................................................................759 CRANKING MOTOR TROUBLESHOOTING..........................................................................................760 Preliminary Inspection..............................................................................................760 No-Load Test........................................................................................................760 Interpreting Results of Tests.......................................................................................760 Disassembly.........................................................................................................761 Cleaning and Inspection.............................................................................................761 Armature Servicing..................................................................................................761 Field Coil Checks...................................................................................................762 Field Coil Removal..................................................................................................762 Solenoid Checks.....................................................................................................764 Test................................................................................................................764 Assembly............................................................................................................765 Pinion Clearance....................................................................................................765 Magnetic Switch.........................................................................................................766 Removal.............................................................................................................766 Installation........................................................................................................766 Coil Test...........................................................................................................766 ELECTRIC START SYSTEM WIRING DIAGRAMS...................................................................................767 HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS)....................................................................................769 GENERAL INFORMATION.....................................................................................................769 TIPS FOR OPERATION......................................................................................................769 DECK MOUNTED LIGHTS.....................................................................................................770 OPERATION AND FUNCTIONS.................................................................................................770 DISPLAY LOGIC...........................................................................................................770 METRIC/SHORT TON SELECTION..............................................................................................770 DATA STORAGE LOGIC......................................................................................................770 DATA PRINT OUT..........................................................................................................771 CLEAR MEMORY............................................................................................................771 SETTING THE TIME OF DAY.................................................................................................771 CALIBRATING THE PAYLOAD METER...........................................................................................772 To perform calibration:.............................................................................................772 DIMMING THE PAYLOAD METER DISPLAY.......................................................................................772 ERROR CODES.............................................................................................................772 SERVICING THE PAYLOAD METER.............................................................................................772 Payload Meter Removal...............................................................................................772 Payload Meter Installation..........................................................................................772 REPLACING PRINTER PAPER.................................................................................................772 Replacing Paper.....................................................................................................773 Troubleshooting Paper Printer.......................................................................................773 REPLACEMENT OF PRINTER MODULE...........................................................................................773 Printer Module Removal..............................................................................................773 Printer Module Installation.........................................................................................775 BATTERY (P/N EC2453)....................................................................................................775 Removal.............................................................................................................775 Installation........................................................................................................775 PRESSURE SENSOR.........................................................................................................775 To Perform A Sensor Check:..........................................................................................776 Removal.............................................................................................................776 Installation........................................................................................................776 INCLINOMETER............................................................................................................776 Removal.............................................................................................................776 Installation........................................................................................................776 RELAYS AND DATA STORAGE TRIGGER MODULE (DSTM)...........................................................................777 CHECK OUT PROCEDURE.....................................................................................................778 Deck Mounted Lights.................................................................................................778 Pressure Sensor Location............................................................................................778 Error Codes.........................................................................................................778 Data storage trigger module.........................................................................................779 Inclinometer........................................................................................................779 Body Up Switch......................................................................................................779 TROUBLESHOOTING THE HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS)................................................................781 ERROR CODES.............................................................................................................781 ON-BOARD WEIGHING SYSTEM EXPANDED MEMORY BOX................................................................................785 DOWNLOAD................................................................................................................785 ANALYSIS................................................................................................................785 Tips For Operation..................................................................................................785 GETTING STARTED.........................................................................................................786 Installing The Software.............................................................................................786 INITIAL START UP OF THE EXPANDED MEMORY BOX.............................................................................786 COMMON PROCEDURES.......................................................................................................787 DOWNLOAD PROGRAM........................................................................................................788 Payload Box.............................................................................................................788 SPECIAL.................................................................................................................791 ANALYSIS PROGRAM........................................................................................................795 PRINTER CHART...........................................................................................................798 HELP MENU...............................................................................................................799 PAYLOAD DATA............................................................................................................800 SERVICE.................................................................................................................802 Removal.............................................................................................................802 Installation........................................................................................................802 Disassembly.........................................................................................................802 Battery Replacement.................................................................................................803 Assembly............................................................................................................803 Wire Connections....................................................................................................803 TROUBLESHOOTING EXPANDED MEMORY BOX.........................................................................................804 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................................................867 AXLE BOX................................................................................................................867 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................................................868 ARMATURE AREA...........................................................................................................868 AT TIRE CHANGE - FOR ALL MOTORIZED WHEELS...............................................................................868 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................................................869 GENERATOR / ALTERNATOR..................................................................................................869 GRID BLOWER MOTOR.......................................................................................................869 CONTROL EQUIPMENT CHECKS................................................................................................869 MOTORIZED WHEEL MAINTENANCE SCHEDULE........................................................................................870 AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM..........................................................................870 VEHICLE OPERATIONS TESTS................................................................................................870 OPERATOR'S CAB..................................................................................................................807 TRUCK CAB...................................................................................................................809 LUBRICATION AND SERVICE.........................................................................................................841 LUBRICATION AND SERVICE.....................................................................................................843 INDEX...........................................................................................................................871 SYSTEM SCHEMATICS...............................................................................................................875
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