Komatsu 830E Dump Truck Shop Manual DG727 – PDF DOWNLOAD

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Komatsu 830E Dump Truck Shop Manual DG727 – PDF DOWNLOAD

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Komatsu 830E Dump Truck Shop Manual DG727 – PDF DOWNLOAD

Language : English
Pages :914
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 830E Dump Truck Shop Manual DG727 – PDF DOWNLOAD

SERIAL SUFFIX
AFE32-DJ – AFE32-DM
AFE32-DS & UP

FOREWORD

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.

TABLE OF CONTENTS:

Komatsu 830E Dump Truck Shop Manual DG727 – PDF DOWNLOAD

SERIAL SUFFIX
AFE32-DJ – AFE32-DM
AFE32-DS & UP

COVER 1
TABLE OF CONTENTS 5
SECTION A – GENERAL INFORMATION 7
GENERAL INFORMATION INDEX 7
GENERAL SAFETY AND OPERATION 13
SAFETY IS THINKING AHEAD 13
Safe practices start before the operator gets to the equipment! 13
PREPARING FOR OPERATION 13
ENGINE START-UP SAFETY PRACTICES 14
AFTER ENGINE HAS STARTED 15
SAFETY PRECAUTIONS DURING TRUCK OPERATION 15
LOADING 16
HAULING 17
PASSING 17
DUMPING 17
To Raise dump body: 18
To Lower Body: 18
TOWING 18
WHEN REPAIRS ARE NECESSARY 19
SAFE PARKING PROCEDURES 20
SHUTDOWN PROCEDURE 20
STANDARD TORQUE CHARTS AND CONVERSION TABLES 27
STORAGE AND IDLE MACHINE PREPARATION 33
SHORT TERM IDLE PERIODS 33
PREPARATION FOR STORAGE 34
REMOVAL FROM STORAGE 35
RECONDITIONING AN IDLE VEHICLE 37
ENGINE OPERATION 40
AFTER ENGINE HAS STARTED 41
ENGINE STORAGE-CUMMINS 42
Engine Storage-(Short Term) 42
Prepare the Engine for Short Term Storage 42
Remove the Engine from Short Term Storage 42
Engine Storage- (Long Term) 43
6 Months to 24 Months 43
Prepare the Engine for Long Term Storage 43
Remove the Engine from Long Term Storage 43
ENGINE STORAGE – DETROIT DIESEL 44
Preparing Engine For Storage 44
Temporary Storage (30 Days Or Less) 44
Extended Storage (more Than 30 Days) 44
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE 46
ELECTRIC DRIVE TRUCKS 47
Storage Instructions and Procedures 47
Placing Equipment Into Storage 47
When Storing A Truck That Is Operational 47
When Storing A Truck That Is Not Operational 48
When Storing A Major Component 48
Periodic Inspections 49
Placing Equipment Into Service After Storage 49
When A Truck Is Operational 49
When A Truck Is Not Operational 49
For The First Hour 50
PRESERVATION AND STORAGE ALLISON TRANSMISSION 51
Storage, New Transmission 51
Storage, One Year — Without Oil 51
Storage, One Year With Oil (normally in a vehicle chassis) 51
Restoring Transmission to Service 51
SECTION B – STRUCTURES 53
STRUCTURES INDEX 53
STRUCTURAL COMPONENTS 55
DUMP BODY 59
SECTION C – ENGINE 65
ENGINE, FUEL, COOLING AND AIR CLEANER INDEX 65
AIR FILTRATION SYSTEM 89
AIR CLEANER 89
Operation 89
General Service Information 89
MAIN FILTER ELEMENT 89
Removal 89
Installation 90
SAFETY FILTER ELEMENT 91
Removal 91
Installation 91
AIR INTAKE TROUBLESHOOTING 91
AIR CLEANER ASSEMBLY CLEANING 91
Main Filter Cleaning 91
Precleaner Section Cleaning 92
SECTION D – ELECTRIC SYSTEM 95
ELECTRIC SYSTEM (24 VDC NON-PROPULSION) INDEX 95
24 VDC ELECTRIC SUPPLY SYSTEM 97
ELECTRICAL SYSTEM DESCRIPTION 97
BATTERY 97
Maintenance and Service 97
Troubleshooting 97
BATTERY CHARGING SYSTEM (Used with DDC and Cummins Engines) 98
General Description 98
Operating Principles 99
Energizing Speed100
Rated Voltage100
Magnetizing The Rotor100
INTEGRAL CHARGING SYSTEM (Battery Charging Alternator)101
Troubleshooting Procedures101
Integral Charging System Repair101
Regulator Check102
Rectifier Bridge Check (Omit for Overcharged Battery)102
Field Coil Checks102
Diode Trio Check103
Stator Checks (Omit for Overcharged Battery)103
Disassembly (Refer to Figure 2-10)103
Reassembly104
SECTION E – ELECTRIC PROPULSION AND CONTROL119
ELECTRICAL PROPULSION AND CONTROL INDEX119
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE195
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE199
GENERAL INFORMATION199
COMMUNICATIONS PORT CHECK200
PTU Hookup200
40 SEQUENCE TESTS – (ENGINE NOT ON)201
Preparation and Setup201
CONTROL SYSTEM SELF-TEST202
41 THROTTLE SYSTEM CHECK AND ADJUSTMENT202
42 RETARD SYSTEM CHECK AND ADJUSTMENT203
PTU Setup203
43 REVERSER AND PROPULSION CONTACTORS CHECK204
44 NOT USED205
45 RETARD CONTACTORS OPERATION CHECK205
46 GROUND FAULT SENSING CHECK205
47 GROUND FAULT IN RETARD OPERATION CHECK206
48 OVERRIDE OPERATION CHECK206
49 ANTI-REVERSAL FUNCTION (AR) CHECK207
410 OVERSPEED RETARD OPERATION CHECK207
411 HOIST INTERLOCK OPERATION CHECK208
412 MOTOR BLOWER FAULT LIGHT OPERATION CHECK208
Return to Main Menu208
50 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL209
51 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU209
52 DIGITAL INPUT CHECKS210
53 DIGITAL OUTPUT CHECKS211
60 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL215
61 SETUP ANALOG INPUT MONITOR SCREEN ON PTU215
62 ANALOG INPUT CHECKS216
63 FREQUENCY INPUT CHECKS220
Return to Main Menu221
70 SPEED EVENT CHECKS221
Preparation and Setup221
Setup PTU221
71 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK222
72 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK222
73 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK222
74 OTHER SPEED EVENTS CHECKS222
Return to Main Menu222
80 RETARD SPEED CONTROL SYSTEM CHECK223
Preparation and Setup223
Setup PTU223
81 OVERSPEED PICKUP AND DROPOUT CHECK223
82 RETARD POT MAXIMUM SETTING CHECK223
83 RETARD POT MINIMUM SETTING CHECK223
84 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL224
Return to Main Menu224
90 LOAD TEST USING TRUCK RETARD GRIDS224
Setup and Preparation224
PTU Setup224
91 LOAD TEST225
100 MOTOR FIELD CURRENT CHECK IN RETARDING225
Setup PTU225
101 RETARD CHECK226
110 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT227
111 BRAKE SYSTEM INTERLOCKS CHECK227
Preparation227
112 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT227
113 SYNC TRANSFORMER CHECKOUT228
114 POWER CONTACTOR POSITION SENSOR ADJUSTMENT228
115 BATTERY BOOST ADJUSTMENT228
116 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST228
117 MOTOR ROTATION TEST229
118 GROUND FAULT CHECKS229
120 MISCELLANEOUS CHARTS230
121 WHEEL MOTOR GEAR RATIOS230
122 MAXIMUM ALLOWABLE TRUCK SPEEDS231
123 ENGINE OPTIONS232
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE TABLE OF CONTENTS233
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS235
DRIVE AXLE, SPINDLE AND WHEELS INDEX235
TIRES AND RIMS237
FRONT TIRES AND RIMS237
Removal237
Installation238
REAR TIRES AND RIMS239
Removal239
Installation240
RIM241
Tire Removal241
RIM AND TIRE PREPARATION241
LUBRICANTS242
TIRE INSTALLATION242
FRONT WHEEL HUB AND SPINDLE245
WHEEL HUB AND SPINDLE ASSEMBLY245
Removal245
Installation247
Disassembly247
Cleaning and Inspection248
Assembly248
Wheel Bearing Adjustment (Tire Removed)250
Wheel Bearing Adjustment (Tire mounted)251
STEERING CYLINDERS AND TIE ROD252
Removal252
Installation252
Bearing Replacement252
TOE-IN ADJUSTMENT254
REAR AXLE HOUSING259
REAR AXLE HOUSING259
Removal259
Installation259
WHEEL MOTOR259
Removal259
Cleaning and Inspection260
Installation260
Maximum Cap Screw Usage260
SECTION H – HYDRAIR SUSPENSIONS261
HYDRAIR II SUSPENSIONS INDEX261
FRONT SUSPENSION263
REAR SUSPENSION271
OILING AND CHARGING PROCEDURE275
GENERAL275
EQUIPMENT LIST275
HYDRAIR® CHARGING KIT275
Installation of Charging Kit275
Removal of Charging Kit276
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS276
FRONT SUSPENSION277
Front Suspension Oiling277
Front Suspension Nitrogen Charging278
REAR SUSPENSION279
Rear Suspension Oiling279
Rear Suspension Nitrogen Charging280
OIL AND NITROGEN SPECIFICATIONS CHART282
SECTION J – BRAKE CIRCUIT283
BRAKE CIRCUIT INDEX283
CARLISLE WHEEL SPEED DISC BRAKES323
BRAKE CALIPERS323
Lining Replacement323
Brake Caliper Removal324
Brake Caliper Installation325
Brake Caliper Disassembly325
Inspection325
Brake Caliper Assembly326
BRAKE CALIPER BENCH TEST327
BRAKE BLEEDING PROCEDURE327
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE328
Front Brake Conditioning328
Temporary Disconnect Procedures For Rear Brakes328
Temporary Disconnect Procedures for Disabling Rear Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks329
Temporary Disconnect Procedures for Disabling Rear Brakes For Model 830E HAULPAK® Trucks329
SPECIAL TOOLS330
ROCKWELL WHEEL SPEED FRONT DISC BRAKES331
BRAKE CALIPER331
Removal331
Installation332
Piston Removal333
Installation333
Caliper Cleaning and Inspection333
BRAKE LINING335
Replacement335
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE336
Front Brake Conditioning336
Temporary Disconnect Procedures For Rear Brakes336
BRAKE BLEEDING PROCEDURES338
CARLISLE ARMATURE SPEED REAR DISC BRAKES339
BRAKE CALIPERS339
Lining Replacement339
Caliper Removal340
Inspection342
Installation343
Disassembly of Brake Calipers344
Inspection346
Caliper Assembly346
BRAKE CALIPER BENCH TEST347
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE348
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE348
General348
Carlisle Armature Speed Disc Brakes Conditioning (Burnishing) Rear Brakes348
BLEEDING PROCEDURE349
TEMPORARY DISCONNECT PROCEDURES FOR DISABLING FRONT BRAKES349
Temporary Disconnect Procedures for Disabling Front Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks350
Temporary Disconnect Procedures for Disabling Front Brakes For Model 830E HAULPAK® Trucks350
ROCKWELL ARMATURE SPEED REAR DISC BRAKES351
REAR BRAKES351
CALIPER, DISC, AND PARKING BRAKE351
Caliper, Disc, And Parking Brake Removal351
Caliper, Disc, And Parking Brake Installation352
CALIPER, DISC, AND PARKING BRAKE REMOVAL354
Caliper, Disc, And Parking Brake Installation355
CALIPER PISTON ASSEMBLY356
Piston Assembly Removal356
Piston Assembly Inspection356
Piston Assembly Installation356
FUNCTIONAL TEST OF PISTON ASSEMBLY357
Return Spring Force357
Built-In Clearance357
Grip Force358
Grip Force Measurement359
Spring Force Measurement360
Disassembly of Piston Assembly361
Assembly of Piston Assembly362
BENCH TEST362
BRAKE LINING363
Replacement363
Brake Pad Conditioning (Burnishing) Procedure365
General365
Conditioning (Burnishing) Rear Brakes365
BLEEDING PROCEDURE366
Temporary Disconnect Procedures for Disabling Front Brakes366
TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Models 630E and 685E Komatsu Trucks367
TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Model 830E Komatsu Trucks367
ROCKWELL DISC PARKING BRAKE369
CALIPER STYLE IDENTIFICATION369
PARK BRAKE CALIPER370
Park Brake Caliper Removal370
Park Brake Caliper Installation370
Parking Brake Adjustment (SCL70)370
Parking Brake Adjustment (SCL15)372
Park Brake Caliper Disassembly373
Cleaning and Inspection374
Park Brake Caliper Assembly375
PARK BRAKE LINING REPLACEMENT375
PARK BRAKE BURNISH PROCEDURE375
Lining Conditioning375
BRAKE BLEEDING PROCEDURE375
CARLISLE DISC PARKING BRAKE377
PARKING BRAKE OPERATION377
TRUCKS WITH ROCKWELL SERVICE BRAKES377
Caliper Removal377
Caliper Installation378
TRUCKS WITH CARLISLE SERVICE BRAKES379
Caliper Removal379
Caliper Installation379
Lining Replacement380
Caliper Disassembly380
Inspection380
Caliper Assembly381
BRAKE CALIPER BENCH TEST382
PARKING BRAKE BLEEDING382
CONDITIONING PROCEDURE FOR DISC PARKING BRAKE382
500 HOUR SERVICE GUIDE FOR DISC PARKING BRAKE383
SECTION K – AIR SYSTEM385
AIR SYSTEM INDEX385
AIR SYSTEM OPERATION385
AIR SYSTEM COMPONENT REPAIR385
AIR STARTER CIRCUIT (If Equipped)385
SECTION L – HYDRAULIC SYSTEM403
HYDRAULIC SYSTEM INDEX403
HYDRAULIC CHECK-OUT PROCEDURE505
STEERING AND BRAKE PUMP505
Pressure Check And Adjustment Procedure505
BLEEDDOWN MANIFOLD506
SHOCK & SUCTION VALVES507
Shock & Suction Valve Settings507
LEAKAGE TESTS507
Steering Control Unit & Flow Amplifier508
Bleed Down Manifold509
TROUBLESHOOTING CHART510
TROUBLESHOOTING CHART513
TROUBLESHOOTING CHART516
CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE518
HYDRAULIC SYSTEM FLUSHING PROCEDURE521
SECTION M – OPTIONS AND SPECIAL TOOLS523
OPTIONS AND SPECIAL TOOLS INDEX523
FIRE CONTROL SYSTEM (MANUAL)527
Operation527
Inspection and Maintenance527
Recharging Procedures528
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM529
SYSTEM ADJUSTMENT529
PUMP529
Removal529
Disassembly529
Inspection531
Assembly531
Installation532
BLOWER DRIVE MOTOR532
Removal533
Disassembly533
Inspection Of Parts534
Assembly534
Installation535
BLOWER BEARING REPAIR535
Removal535
Replacement535
Assembly536
AIR CLEANER536
Assembly536
Removal536
Washing Air Cleaner536
Assembly536
WIGGINS QUICK FILL FUEL SYSTEM537
FUEL RECEIVER537
TANK BREATHER VALVE538
Removal538
Installation538
Disassembly538
Assembly538
LEFT SIDE FILL539
BUCKEYE QUICK FUEL SYSTEM541
FUEL TANK BREATHER VALVE541
Maintenance541
Filter Service541
Disassembly541
Inspection541
Assembly541
FUEL RECEIVER542
FAN DRIVE CLUTCH543
GENERAL DESCRIPTION543
COMPONENTS543
Input543
Output544
Stationary Components544
OPERATION MODES544
Fully Engaged544
Modulated Variable Speed545
Fully Released545
Remember:545
Lubricating & Cooling Oil545
MAINTENANCE546
Maintenance Checks To Be Made546
TROUBLE SHOOTING548
Basic Preliminary Checks548
FIELD CHECK DIAGNOSIS549
Preliminary Checks With Engine Off549
Check Clutch Release549
Check Clutch Lock-up549
Overheating Complaint550
Thermal Sensor And Solenoid Valve550
On Truck Test550
Off Truck Test551
Test Conditions and Requirements:551
TEST:551
TROUBLESHOOTING CHART553
PROBABLE CAUSES553
SUGGESTED CORRECTIVE ACTIONS553
PROBABLE CAUSES554
SUGGESTED CORRECTIVE ACTIONS554
PROBABLE CAUSES555
SUGGESTED CORRECTIVE ACTIONS555
FAN CLUTCH DISASSEMBLY INSTRUCTIONS557
REASSEMBLY OF THE FAN CLUTCH564
INSPECTION OF PARTS575
REBUILD TOOLS580
ENGINE COOLANT HEATER581
Maintenance581
HEATING ELEMENT581
Removal581
Installation581
THERMOSTAT582
Removal582
Installation582
SPECIAL TOOLS585
AIR CONDITIONING SYSTEM591
Environmental Impact591
OPERATOR CAB AIR CONDITIONING592
PRINCIPLES OF REFRIGERATION592
Air Conditioning592
Refrigeration – The Act Of Cooling593
The Refrigeration Cycle593
AIR CONDITIONER SYSTEM COMPONENTS594
Compressor (Refrigerant Pump)594
Service Valves594
Condenser594
Expansion Block Valve595
Evaporator595
ELECTRICAL CIRCUIT596
Thermostat596
Compressor Clutch596
Trinary™ Switch597
SYSTEM SERVICING598
SYSTEM OIL599
Handling and Reusing PAG Oil599
Oil Quantity599
Replacing Oil After Servicing the System599
Setting Up a New Compressor599
REFRIGERANT600
Recycled Refrigerant600
Reclaimed Refrigerant600
Refrigerant Quantity600
R-134a Refrigerant Containers600
SERVICE TOOLS AND EQUIPMENT601
Recovery/Recycle Station601
Leak Detector601
Service Valves602
Vacuum Pump602
Manifold Gauge Set603
Installing Manifold Gauge Set604
Purging Air From Service Hoses605
Stabilizing the AC System606
SYSTEM PERFORMANCE TEST606
SYSTEM LEAK TESTING607
Electronic leak detector607
Tracer dyes607
Soap and water607
SYSTEM REPAIR608
System Cleaning608
Hoses and Fittings608
Lines608
Expansion Valve608
Receiver-Drier609
Thermostat609
Compressor609
Clutch609
Servicing the Compressor Clutch610
Pulley Removal612
Clutch Coil Check612
Pulley Installation612
Clutch Assembly Installation613
RECOVERING AND RECYCLING THE REFRIGERANT614
Performing the Recovery Cycle614
Performing the Recycling Procedure614
Evacuating and Charging the AC System614
EVACUATING THE SYSTEM615
CHARGING THE AC SYSTEM616
TROUBLESHOOTING617
Pre-Diagnosis Checks617
Preparing For Diagnosis617
Preliminary Steps617
System Performance Test617
Diagnosis Of Gauge Readings And System Performance618
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM625
AFTERCOOLER OPERATION AND REPAIR631
OPERATION631
MAINTENANCE631
Removal631
Installation631
Disassembly632
Cleaning and Inspection633
Assembly633
AIR DRYER (AEROFINER III)635
AIR DRYER635
Service635
Indications To Change Desiccant635
Removal636
Installation636
Disassembly636
Assembly637
CHECK VALVE637
Removal637
Installation637
PURGE VALVE & HEATER638
Removal638
Inspection638
Installation638
24VDC ELECTRIC SUPPLY SYSTEM651
ELECTRICAL SYSTEM DESCRIPTION651
BATTERY651
Maintenance and Service651
Troubleshooting651
BATTERY CHARGING SYSTEM (Niehoff)653
General Description653
TROUBLESHOOTING PROCEDURES (On- Truck)653
Equipment Required:653
Preliminary Checks654
Test Setup654
Test Procedure654
Regulator Bypass Test655
ON VEHICLE TROUBLESHOOTING GUIDE657
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage657
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:657
CHARGE VOLT AND AMP VALUES658
DEFINITIONS658
ADVANCED SYSTEM TROUBLESHOOTING659
Static Test – Engine OFF, Key ON, Battery Switch ON659
Go To Alternator659
Go To Regulator (If Required)660
Go To Regulator Connector On The Alternator660
NIEHOFF Alternator Overhaul Manual661
TABLE OF CONTENTS661
ALTERNATOR SPECIFICATIONS663
ON-VEHICLE TEST666
Equipment:666
Preliminary Checks:666
Test Set-up666
Test Procedure666
ON-VEHICLE TEST667
Bypass Test:667
BENCH TEST668
Equipment:668
TEST 1 – NO-LOAD TEST668
TEST 2 – FULL LOAD TEST668
TEST 3 – REGULATOR BYPASS TEST668
STATIC TESTS669
EQUIPMENT:669
REGULATOR TESTS669
TEST 1 – Check For Shorted Output Transistor669
TEST 2 – Check Function Of Clamping Diode669
FIELD COIL TESTS669
TEST 3 – Check For Open Field Coil669
TEST 4 – Check For Grounded Field Coil670
CONTROL BOX TESTS670
TEST 5 – Check Continuity Of Terminal Strip Connections670
TEST 6 – Diode Heat Sink Tests670
TEST 7 – Check Positive Diodes671
TEST 8 – Check Negative Diodes671
TEST 9 – Check Front & Rear Stator671
ALTERNATOR DISASSEMBLY672
FAN REMOVAL672
PULLEY REMOVAL672
REGULATOR REMOVAL672
END HOUSING REMOVAL673
REAR ROTOR REMOVAL673
Alternate Method673
REAR BEARING REMOVAL673
FRONT HOUSING REMOVAL674
CONTROL UNIT ASSEMBLY REMOVAL675
FRONT BEARING REMOVAL676
FRONT ROTOR REMOVAL676
Alternate Method676
FIELD COIL REMOVAL676
ALTERNATOR ASSEMBLY677
FIELD COIL ASSEMBLY677
FRONT BEARING ASSEMBLY678
FRONT ROTOR ASSEMBLY679
FRONT HOUSING – STATOR, FIELD COIL & SHELL ASSEMBLY680
REAR ROTOR ASSEMBLY682
CONTROL UNIT ASSEMBLY REPLACEMENT681
END HOUSING ASSEMBLY682
REAR BEARING ASSEMBLY684
PRESS FIT REAR BEARINGS684
LOOSE FIT REAR BEARINGS684
REGULATOR ASSEMBLY684
FAN ASSEMBLY685
PULLEY ASSEMBLY685
BF4822 STATOR SERVICE TOOL INSTRUCTIONS686
Function of Service Tool686
STATOR REMOVAL AND REPLACEMENT686
Pressure Plate Set-up (Refer to Figure 13-42)686
STATOR INSTALLATION (Refer to Figure 13-41)687
PRESSURE PLATE SET UP (Refer to Figure 13- 42)688
OPTIONAL OPERATOR SEAT689
SEAT689
Removal689
Installation689
Disassembly690
Assembly692
Air Suspension Cam Adjustment693
SEAT MAINTENANCE AND REPAIR694
Headrest694
Backrest694
Armrests694
Seat Cushion694
Seat Frame694
Slides695
Suspension695
TDI SINGLE STAGE AIR STARTER697
STARTER697
Removal697
Installation697
Disassembly697
Cleaning701
Parts Inspection701
PARTS INSPECTION (Refer to Figure 15-2 for reference to parts)702
Assembly704
AUTOMATIC TRIP VALVE708
Disassembly708
Reassembly708
Operation Check709
TDI TWO-STAGE AIR STARTER711
AIR STARTER711
Removal711
Installation711
Description of Basic Groups711
Disassembly714
Cleaning and Inspection716
Assembly718
TDI TWO-STAGE AIR STARTER TROUBLESHOOTING GUIDE724
M15001 – TDI AIR STARTER TABLE OF CONTENTS725
INGERSOLL-RAND TURBINE POWERED STARTER727
MAINTENANCE727
Removal727
Installation727
Disassembly Tips727
Disassembly – Housing Exhaust Cover, Motor Assembly, and Motor Housing730
Disassembly – Drive Housing732
Assembly Tips734
Lubrication734
Assembly – Gear Case and Drive Housing735
Assembly – Intermediate Gear Case, Motor Housing, Motor Assembly, and Housing Exhaust Cover736
TEST AND INSPECTION PROCEDURE741
TROUBLESHOOTING CHART742
24 VDC ELECTRIC START SYSTEM755
OPERATION755
CRANKING MOTOR755
Removal755
Installation755
CRANKING MOTOR TROUBLESHOOTING756
Preliminary Inspection756
No-Load Test756
Interpreting Results of Tests756
Disassembly757
Cleaning and Inspection757
Armature Servicing757
Field Coil Checks758
Field Coil Removal758
Solenoid Checks760
Test760
Assembly761
Pinion Clearance761
Magnetic Switch762
Removal762
Installation762
Coil Test762
ELECTRIC START SYSTEM WIRING DIAGRAMS763
SECTION N – OPERATOR’S CAB803
OPERATOR’S CAB INDEX803
CAB COMPONENTS811
WINDSHIELD WIPER811
Removal811
Installation811
WINDSHIELD WASHER812
Operation812
Service812
SECTION P – LUBRICATION AND SERVICE837
LUBRICATION AND SERVICE INDEX837
MOTORIZED WHEEL MAINTENANCE SCHEDULE863
AXLE BOX863
MOTORIZED WHEEL MAINTENANCE SCHEDULE864
ARMATURE AREA864
AT TIRE CHANGE – FOR ALL MOTORIZED WHEELS864
MOTORIZED WHEEL MAINTENANCE SCHEDULE865
GENERATOR / ALTERNATOR865
GRID BLOWER MOTOR865
CONTROL EQUIPMENT CHECKS865
MOTORIZED WHEEL MAINTENANCE SCHEDULE866
AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM866
VEHICLE OPERATIONS TESTS866
SECTION Q – ALPHABETICAL INDEX867
SECTION R – SYSTEM SCHEMATICS871
SYSTEM SCHEMATICS INDEX871

IMAGES PREVIEW OF THE MANUAL:

S.M 18/12/24