Komatsu 830E Dump Truck Shop Manual SN A30544-A30606 – PDF DOWNLOAD

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Komatsu 830E Dump Truck Shop Manual

FILE DETAILS:

Komatsu 830E Dump Truck Shop Manual

Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 830E
Serial Number: A30544 – A30606
Language: English
Pages: 787
File Format: Portable Document Format (PDF)

KOMATSU 830E DUMP TRUCK SHOP MANUAL SN A30544-A30606 – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu 830E Dump Truck Shop Manual

FOREWORD:

This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.

• The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
• Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±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 KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. 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

COVER.............................................................................................................  1
SECTION A - GENERAL INFORMATION...................................................................................  3
	FOREWARD......................................................................................................  3
	CONTENTS......................................................................................................  5
	GENERAL INFORMATION INDEX.....................................................................................  7
		STORAGE AND IDLE MACHINE PREPARATION...................................................................... 47
			SHORT TERM IDLE PERIODS............................................................................... 47
		PREPARATION FOR STORAGE................................................................................... 48
			REMOVAL FROM STORAGE.................................................................................. 49
			RECONDITIONING AN IDLE VEHICLE........................................................................ 51
			ENGINE OPERATION...................................................................................... 54
			AFTER ENGINE HAS STARTED.............................................................................. 55
			ENGINE STORAGE-CUMMINS................................................................................ 56
				Engine Storage-(Short Term)....................................................................... 56
				Prepare the Engine for Short Term Storage......................................................... 56
				Remove the Engine from Short Term Storage......................................................... 56
				Engine Storage- (Long Term)....................................................................... 57
					6 Months to 24 Months......................................................................... 57
					Prepare the Engine for Long Term Storage...................................................... 57
					Remove the Engine from Long Term Storage...................................................... 57
			ENGINE STORAGE - DETROIT DIESEL....................................................................... 58
				Preparing Engine For Storage...................................................................... 58
				Temporary Storage (30 Days Or Less)............................................................... 58
				Extended Storage (more Than 30 Days).............................................................. 58
			PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE....................... 60
			ELECTRIC DRIVE TRUCKS................................................................................. 61
				Storage Instructions and Procedures............................................................... 61
				Placing Equipment Into Storage.................................................................... 61
				When Storing A Truck That Is Operational.......................................................... 61
				When Storing A Truck That Is Not Operational...................................................... 62
				When Storing A Major Component.................................................................... 62
				Periodic Inspections.............................................................................. 63
				Placing Equipment Into Service After Storage...................................................... 63
				When A Truck Is Operational....................................................................... 63
				When A Truck Is Not Operational................................................................... 63
				For The First Hour................................................................................ 64
			PRESERVATION AND STORAGE ALLISON TRANSMISSION......................................................... 65
				Storage, New Transmission......................................................................... 65
				Storage, One Year -- Without Oil.................................................................. 65
				Storage, One Year With Oil (normally in a vehicle chassis)........................................ 65
				Restoring Transmission to Service................................................................. 65
SECTION B - STRUCTURES............................................................................................ 67
	STRUCTURES INDEX.............................................................................................. 67
		RIGHT HAND DECK........................................................................................... 69
			Removal............................................................................................... 69
			Installation.......................................................................................... 70
		CENTER AND LEFT HAND DECK COMPONENTS...................................................................... 70
		FUEL TANK................................................................................................. 71
			Removal............................................................................................... 71
			Installation.......................................................................................... 71
SECTION C - ENGINE, FUEL, COOLING AND AIR CLEANER................................................................. 79
	POWER TRAIN INDEX............................................................................................. 93
		POWER TRAIN............................................................................................... 95
			ALTERNATOR REMOVAL PROCEDURE.......................................................................... 95
				Removal (MTU/DDC 4000 Engine)..................................................................... 95
			ENGINE/ALTERNATOR MATING.............................................................................. 97
				General Instructions.............................................................................. 97
				MEASURING PROCEDURE............................................................................... 97
					Joining Alternator and MTU/DDC Engine......................................................... 99
			ENGINE................................................................................................100
				Removal...........................................................................................100
				Service...........................................................................................100
				Installation......................................................................................100
		AIR FILTRATION SYSTEM.....................................................................................101
			AIR CLEANER...........................................................................................101
				Operation.........................................................................................101
				General Service Information.......................................................................101
			MAIN FILTER ELEMENT...................................................................................101
				Removal...........................................................................................101
				Installation......................................................................................102
			SAFETY FILTER ELEMENT.................................................................................103
				Removal...........................................................................................103
				Installation......................................................................................103
			AIR INTAKE TROUBLESHOOTING............................................................................103
			AIR CLEANER ASSEMBLY CLEANING.........................................................................103
				Main Filter Cleaning..............................................................................103
				Precleaner Section Cleaning.......................................................................104
SECTION D - ELECTRIC SYSTEM (24VDC NON-PROPULSION)................................................................107
	ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX................................................................107
		24VDC ELECTRICAL SYSTEM COMPONENTS........................................................................119
			ALARM INDICATING DEVICE (AID).........................................................................119
				Coolant Level/Flasher Card........................................................................119
				Temperature/Latch Card............................................................................119
				Oil Level Card....................................................................................120
				Temperature Card..................................................................................120
				Hot Switch Inverter Card (Slot 4).................................................................120
				Hot Switch Inverter Card (Slot 3).................................................................120
				Diode Matrix Without Sound Card...................................................................120
				Diode Matrix With Sound Card......................................................................120
			BODY-UP SWITCH........................................................................................120
				Adjustment........................................................................................121
				Service...........................................................................................121
			HOIST LIMIT SWITCH....................................................................................121
				Adjustment........................................................................................121
				Service...........................................................................................121
			BATTERY EQUALIZER.....................................................................................122
				Troubleshooting...................................................................................122
			GROUND LEVEL SHUTDOWN.................................................................................122
			24 VOLT RELAY AND DIODE BOARDS........................................................................123
				RELAY BOARDS......................................................................................123
					Description...................................................................................123
			SERVICE...............................................................................................124
			RELAY BOARD COMPONENTS................................................................................125
				Relay Board 1 Turn Signal.........................................................................125
				Relay Board 2 Payload Meter (Optional)............................................................125
				Relay Board 3 Stop Lights.........................................................................126
				Relay Board 4 Parking Brake.......................................................................126
				Relay Board 5 Head Lights.........................................................................126
				Relay Board 6 Auxiliary Panel.....................................................................127
			DIODE BOARD 1.........................................................................................128
				Diode Testing.....................................................................................128
			CIRCUIT BREAKERS......................................................................................128
		DDEC ELECTRONIC ENGINE CONTROL INDEX......................................................................131
			DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE.........................................133
				COMPONENT DESCRIPTION.............................................................................134
					Electronic Control Module.....................................................................134
					Electronic Unit Nozzles.......................................................................136
					System Sensors and Operator Inputs............................................................136
				ENGINE PROTECTION SYSTEM..........................................................................137
				DIAGNOSTICS.......................................................................................138
SECTION E - ELECTRICAL PROPULTION AND CONTROL.....................................................................139
	STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX.........................................................215
		STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE...........................................................219
			GENERAL INFORMATION...................................................................................219
			COMMUNICATIONS PORT CHECK.............................................................................220
				PTU Hookup........................................................................................220
			4.0 SEQUENCE TESTS - (ENGINE NOT ON)..................................................................221
				Preparation and Setup.............................................................................221
			CONTROL SYSTEM SELF-TEST..............................................................................222
			4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT..............................................................222
			4.2 RETARD SYSTEM CHECK AND ADJUSTMENT................................................................223
				PTU Setup.........................................................................................223
			4.3 REVERSER AND PROPULSION CONTACTORS CHECK..........................................................224
			4.4 NOT USED..........................................................................................225
			4.5 RETARD CONTACTORS OPERATION CHECK.................................................................225
			4.6 GROUND FAULT SENSING CHECK........................................................................225
			4.7 GROUND FAULT IN RETARD OPERATION CHECK............................................................226
			4.8 OVERRIDE OPERATION CHECK..........................................................................226
			4.9 ANTI-REVERSAL FUNCTION (AR) CHECK.................................................................227
			4.10 OVERSPEED RETARD OPERATION CHECK.................................................................227
			4.11 HOIST INTERLOCK OPERATION CHECK..................................................................228
			4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.........................................................228
				Return to Main Menu...............................................................................228
			5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL..............................................229
			5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.....................................................229
			5.2 DIGITAL INPUT CHECKS..............................................................................230
			5.3 DIGITAL OUTPUT CHECKS.............................................................................231
			6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL......................................................235
			6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU..........................................................235
			6.2 ANALOG INPUT CHECKS...............................................................................236
			6.3 FREQUENCY INPUT CHECKS............................................................................240
				Return to Main Menu...............................................................................241
			7.0 SPEED EVENT CHECKS................................................................................241
				Preparation and Setup.............................................................................241
				Setup PTU.........................................................................................241
			7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK...........................................242
			7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK................................242
			7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK...............................242
			7.4 OTHER SPEED EVENTS CHECKS.........................................................................242
				Return to Main Menu...............................................................................242
			8.0 RETARD SPEED CONTROL SYSTEM CHECK.................................................................243
				Preparation and Setup.............................................................................243
				Setup PTU.........................................................................................243
			8.1 OVERSPEED PICKUP AND DROPOUT CHECK................................................................243
			8.2 RETARD POT MAXIMUM SETTING CHECK..................................................................243
			8.3 RETARD POT MINIMUM SETTING CHECK..................................................................243
			8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL................................................244
				Return to Main Menu...............................................................................244
			9.0 LOAD TEST USING TRUCK RETARD GRIDS................................................................244
				Setup and Preparation.............................................................................244
				PTU Setup.........................................................................................244
			9.1 LOAD TEST.........................................................................................245
			10.0 MOTOR FIELD CURRENT CHECK IN RETARDING...........................................................245
				Setup PTU.........................................................................................245
			10.1 RETARD CHECK.....................................................................................246
			11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT......................................................247
			11.1 BRAKE SYSTEM INTERLOCKS CHECK....................................................................247
				Preparation.......................................................................................247
			11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT...........................................................247
			11.3 SYNC TRANSFORMER CHECKOUT........................................................................248
			11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT.......................................................248
			11.5 BATTERY BOOST ADJUSTMENT.........................................................................248
			11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST......................................................248
			11.7 MOTOR ROTATION TEST..............................................................................249
			11.8 GROUND FAULT CHECKS..............................................................................249
			12.0 MISCELLANEOUS CHARTS.............................................................................250
			12.1 WHEEL MOTOR GEAR RATIOS..........................................................................250
			12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS...................................................................251
			12.3 ENGINE OPTIONS...................................................................................252
SECTION G - DRIVE AXLE, SPINDLES AND WHEELS.......................................................................255
	DRIVE AXLE, SPINDLE AND WHEELS INDEX..........................................................................255
		TIRES AND RIMS............................................................................................257
			FRONT TIRES AND RIMS..................................................................................257
				Removal...........................................................................................257
				Installation......................................................................................258
			REAR TIRES AND RIMS...................................................................................259
				Removal...........................................................................................259
				Installation......................................................................................260
			RIM...................................................................................................261
				Tire Removal......................................................................................261
			RIM AND TIRE PREPARATION..............................................................................261
			LUBRICANTS............................................................................................262
			TIRE INSTALLATION.....................................................................................262
			FRONT WHEEL HUB AND SPINDLE...........................................................................265
			WHEEL HUB AND SPINDLE ASSEMBLY........................................................................265
				Removal...........................................................................................265
				Spindle Pusher Tool Usage.........................................................................266
				Installation......................................................................................267
				Disassembly.......................................................................................269
				Cleaning and Inspection...........................................................................269
				Assembly..........................................................................................270
				Wheel Bearing Adjustment (Tire Removed)...........................................................272
				Wheel Bearing Adjustment (Tire mounted)...........................................................272
			STEERING CYLINDERS AND TIE ROD........................................................................274
				Spherical Bearing Wear Limits.....................................................................274
				Removal...........................................................................................275
				Installation......................................................................................275
				Bearing Replacement...............................................................................275
			TOE-IN ADJUSTMENT.....................................................................................277
		REAR AXLE HOUSING ATTACHMENT..............................................................................279
			PIVOT PIN.............................................................................................279
				Removal...........................................................................................279
				Installation......................................................................................279
			PIVOT EYE BEARING.....................................................................................280
				Disassembly.......................................................................................280
				Assembly..........................................................................................280
			PIVOT EYE REPAIR......................................................................................281
				Removal...........................................................................................281
				Disassembly.......................................................................................281
				Assembly..........................................................................................281
				Installation......................................................................................281
			ANTI-SWAY BAR.........................................................................................282
				Removal...........................................................................................282
				Installation......................................................................................282
				Disassembly.......................................................................................282
				Cleaning and Inspection...........................................................................282
				Assembly..........................................................................................282
		REAR AXLE HOUSING.........................................................................................283
			REAR AXLE HOUSING.....................................................................................283
				Removal...........................................................................................283
				Installation......................................................................................283
			WHEEL MOTOR...........................................................................................283
				Removal...........................................................................................283
				Cleaning and Inspection...........................................................................284
				Installation......................................................................................284
				Maximum Cap Screw Usage...........................................................................284
		OILING AND CHARGING PROCEDURE.............................................................................299
			GENERAL...............................................................................................299
			EQUIPMENT LIST........................................................................................299
			HYDRAIR® CHARGING KIT.................................................................................299
				Installation of Charging Kit......................................................................299
				Removal of Charging Kit...........................................................................300
			SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS.....................................................300
			FRONT SUSPENSION......................................................................................301
				Front Suspension Oiling...........................................................................301
				Front Suspension Nitrogen Charging................................................................302
			REAR SUSPENSION.......................................................................................303
				Rear Suspension Oiling............................................................................303
				Rear Suspension Nitrogen Charging.................................................................304
		OIL AND NITROGEN SPECIFICATIONS CHART.....................................................................306
SECTION H - HYDRAIR II SUSPENSIONS................................................................................285
	HYDRAIR II SUSPENSIONS INDEX..................................................................................285
SECTION J - BRAKE CIRCUIT.........................................................................................307
	BRAKE CIRCUIT INDEX...........................................................................................307
		BRAKE CIRCUIT COMPONENT SERVICE...........................................................................315
			BRAKE VALVE...........................................................................................315
				Rebuild Criteria..................................................................................315
				Removal...........................................................................................315
			DISASSEMBLY...........................................................................................318
				Cleaning and Inspection...........................................................................320
			ASSEMBLY..............................................................................................320
				Actuator Base Threaded Inserts....................................................................320
				Boot and Cap......................................................................................320
				Valve Body Seal Installation......................................................................321
				Regulator Sleeve O-Ring Installation..............................................................321
				Actuator Plunger O-ring Installation..............................................................321
				Assembly of Valve.................................................................................322
			DIFFERENTIAL PRESSURE SWITCH..........................................................................323
				Disassembly.......................................................................................323
				Cleaning and Inspection...........................................................................323
				Assembly..........................................................................................323
			VALVE BENCH TEST AND ADJUSTMENT.......................................................................324
				Test Set Up Procedure.............................................................................325
				Brake Valve Output Pressure Adjustment............................................................325
				Differential Pressure Switch Test.................................................................325
				Final Test and Adjustment.........................................................................326
				Installation Of Brake Pedal Actuator Assembly to Brake Valve......................................327
			BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal)..................328
				Installation of Retard Pedal To Brake Pedal.......................................................328
			HYDRAULIC BRAKE ACCUMULATORS..........................................................................329
				Brake Accumulator Bleed Down Procedure............................................................329
				Removal...........................................................................................329
				Installation......................................................................................329
				Disassembly.......................................................................................329
				Cleaning and Inspection...........................................................................330
				Assembly..........................................................................................331
				Charging Procedure................................................................................332
			BRAKE MANIFOLD........................................................................................333
				Removal...........................................................................................333
				Removal...........................................................................................333
				Installation......................................................................................334
				Disassembly.......................................................................................334
				Cleaning and Inspection...........................................................................334
				Assembly..........................................................................................334
		BRAKE CIRCUIT CHECK-OUT PROCEDURE.........................................................................335
			EQUIPMENT REQUIRED....................................................................................337
			INITIAL SYSTEM SET-UP.................................................................................338
			PARKING BRAKE.........................................................................................338
			BRAKE SYSTEM CHECK-OUT................................................................................338
				Failure Modes Check-Out...........................................................................339
		BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING.............................................................341
		KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.............................................345
		KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET.................................................346
		ROCKWELL WHEEL SPEED FRONT DISC BRAKES....................................................................347
			BRAKE CALIPER.........................................................................................347
				Removal...........................................................................................347
				Installation......................................................................................348
				Piston Removal....................................................................................349
				Installation......................................................................................349
				Caliper Cleaning and Inspection...................................................................349
			BRAKE LINING..........................................................................................351
				Replacement.......................................................................................351
			SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.....................................................352
				Front Brake Conditioning..........................................................................352
				Temporary Disconnect Procedures For Rear Brakes...................................................352
			BRAKE BLEEDING PROCEDURES.............................................................................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
SECTION K - AIR SYSTEM............................................................................................381
	AIR SYSTEM INDEX..............................................................................................381
		AIR SYSTEM OPERATION......................................................................................383
		AIR SYSTEM COMPONENT REPAIR...............................................................................387
SECTION L - HYDRAULIC SYSTEM......................................................................................393
	HYDRAULIC SYSTEM INDEX........................................................................................393
		HYDRAULIC CHECK-OUT PROCEDURE.............................................................................503
			STEERING AND BRAKE PUMP...............................................................................503
				Pressure Check And Adjustment Procedure...........................................................503
			BLEEDDOWN MANIFOLD....................................................................................504
			SHOCK & SUCTION VALVES................................................................................505
				Shock & Suction Valve Settings....................................................................505
			LEAKAGE TESTS.........................................................................................505
				Steering Control Unit & Flow Amplifier............................................................506
				Bleed Down Manifold...............................................................................507
			TROUBLESHOOTING CHART.................................................................................508
			TROUBLESHOOTING CHART.................................................................................511
			TROUBLESHOOTING CHART.................................................................................514
			CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE...........................................................516
			HYDRAULIC SYSTEM FLUSHING PROCEDURE...................................................................519
SECTION M - OPTIONS AND SPECIAL TOOLS.............................................................................521
	OPTIONS AND SPECIAL TOOLS INDEX...............................................................................521
		FIRE CONTROL SYSTEM (MANUAL)..............................................................................523
			Operation.............................................................................................523
			Inspection and Maintenance............................................................................523
			Recharging Procedures.................................................................................524
		ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM.......................................................525
			SYSTEM ADJUSTMENT.....................................................................................525
				PUMP..............................................................................................525
					Removal.......................................................................................525
					Disassembly...................................................................................525
					Inspection....................................................................................527
					Assembly......................................................................................527
					Installation..................................................................................528
			BLOWER DRIVE MOTOR....................................................................................528
				Removal...........................................................................................529
				Disassembly.......................................................................................529
				Inspection Of Parts...............................................................................530
				Assembly..........................................................................................530
				Installation......................................................................................531
			BLOWER BEARING REPAIR.................................................................................531
				Removal...........................................................................................531
				Replacement.......................................................................................531
				Assembly..........................................................................................532
			AIR CLEANER...........................................................................................532
				Assembly..........................................................................................532
				Removal...........................................................................................532
				Washing Air Cleaner...............................................................................532
				Assembly..........................................................................................532
		WIGGINS QUICK FILL FUEL SYSTEM............................................................................533
			FUEL RECEIVER.........................................................................................533
			TANK BREATHER VALVE...................................................................................534
				Removal...........................................................................................534
				Installation......................................................................................534
				Disassembly.......................................................................................534
				Assembly..........................................................................................534
			LEFT SIDE FILL........................................................................................535
		BUCKEYE QUICK FUEL SYSTEM.................................................................................537
			FUEL TANK BREATHER VALVE..............................................................................537
				Maintenance.......................................................................................537
				Filter Service....................................................................................537
				Disassembly.......................................................................................537
				Inspection........................................................................................537
				Assembly..........................................................................................537
			FUEL RECEIVER.........................................................................................538
		ENGINE COOLANT HEATER.....................................................................................539
			Maintenance...........................................................................................539
			HEATING ELEMENT.......................................................................................539
				Removal...........................................................................................539
				Installation......................................................................................539
			THERMOSTAT............................................................................................540
				Removal...........................................................................................540
				Installation......................................................................................540
		SPECIAL TOOLS.............................................................................................541
		AIR CONDITIONING SYSTEM...................................................................................547
			Environmental Impact..................................................................................547
			OPERATOR CAB AIR CONDITIONING.........................................................................548
			PRINCIPLES OF REFRIGERATION...........................................................................548
				Air Conditioning..................................................................................548
				Refrigeration - The Act Of Cooling................................................................549
				The Refrigeration Cycle...........................................................................549
			AIR CONDITIONER SYSTEM COMPONENTS.....................................................................550
				Compressor (Refrigerant Pump).....................................................................550
				Service Valves....................................................................................550
				Condenser.........................................................................................550
				Expansion Block Valve.............................................................................551
				Evaporator........................................................................................551
			ELECTRICAL CIRCUIT....................................................................................552
				Thermostat........................................................................................552
				Compressor Clutch.................................................................................552
				Trinary™ Switch...................................................................................553
			SYSTEM SERVICING......................................................................................554
			SYSTEM OIL............................................................................................555
				Handling and Reusing PAG Oil......................................................................555
				Oil Quantity......................................................................................555
				Replacing Oil After Servicing the System..........................................................555
				Setting Up a New Compressor.......................................................................555
			REFRIGERANT...........................................................................................556
				Recycled Refrigerant..............................................................................556
				Reclaimed Refrigerant.............................................................................556
				Refrigerant Quantity..............................................................................556
				R-134a Refrigerant Containers.....................................................................556
			SERVICE TOOLS AND EQUIPMENT...........................................................................557
				Recovery/Recycle Station..........................................................................557
				Leak Detector.....................................................................................557
				Service Valves....................................................................................558
				Vacuum Pump.......................................................................................558
				Manifold Gauge Set................................................................................559
				Installing Manifold Gauge Set.....................................................................560
				Purging Air From Service Hoses....................................................................561
				Stabilizing the AC System.........................................................................562
			SYSTEM PERFORMANCE TEST...............................................................................562
			SYSTEM LEAK TESTING...................................................................................563
				Electronic leak detector..........................................................................563
				Tracer dyes.......................................................................................563
				Soap and water....................................................................................563
			SYSTEM REPAIR.........................................................................................564
				System Cleaning...................................................................................564
				Hoses and Fittings................................................................................564
				Lines.............................................................................................564
				Expansion Valve...................................................................................564
				Receiver-Drier....................................................................................565
				Thermostat........................................................................................565
				Compressor........................................................................................565
				Clutch............................................................................................565
				Servicing the Compressor Clutch...................................................................566
				Pulley Removal....................................................................................568
				Clutch Coil Check.................................................................................568
				Pulley Installation...............................................................................568
				Clutch Assembly Installation......................................................................569
			RECOVERING AND RECYCLING THE REFRIGERANT..............................................................570
				Performing the Recovery Cycle.....................................................................570
				Performing the Recycling Procedure................................................................570
				Evacuating and Charging the AC System.............................................................570
			EVACUATING THE SYSTEM.................................................................................571
			CHARGING THE AC SYSTEM................................................................................572
			TROUBLESHOOTING.......................................................................................573
				Pre-Diagnosis Checks..............................................................................573
				Preparing For Diagnosis...........................................................................573
				Preliminary Steps.................................................................................573
				System Performance Test...........................................................................573
				Diagnosis Of Gauge Readings And System Performance................................................574
			PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM.......................................................581
		AIR DRYER (AEROFINER III).................................................................................583
			AIR DRYER.............................................................................................583
				Service...........................................................................................583
				Indications To Change Desiccant...................................................................583
				Removal...........................................................................................584
				Installation......................................................................................584
				Disassembly.......................................................................................584
				Assembly..........................................................................................585
			CHECK VALVE...........................................................................................585
				Removal...........................................................................................585
				Installation......................................................................................585
				PURGE VALVE & HEATER..............................................................................586
				Removal...........................................................................................586
				Inspection........................................................................................586
				Installation......................................................................................586
		PAYLOAD METER II - ON BOARD WEIGHING SYSTEM INDEX.........................................................587
			PAYLOAD METER II - ON BOARD WEIGHING SYSTEM...........................................................589
				GENERAL INFORMATION...............................................................................589
					Haul Cycles...................................................................................589
				LIGHTS, SWITCHES AND COMPONENTS...................................................................590
				TIPS FOR OPERATION................................................................................591
				EXTERNAL DISPLAY LIGHTS...........................................................................591
				THEORY OF OPERATION...............................................................................592
					Basic Description.............................................................................592
					Inclinometer..................................................................................592
					Linkage Factor................................................................................592
					Gain Factor...................................................................................593
					Brake Lock....................................................................................593
					Sources of Error..............................................................................593
					Typical Data From Service Check Mode..........................................................593
					Example Calculation of Payload................................................................594
					Viewing Payload Calculation Inputs............................................................594
					Checking the Gain.............................................................................595
					Adjusting the Gain............................................................................595
				TYPES OF DATA STORED..............................................................................596
					Cycle Data....................................................................................596
					Engine ON/OFF Data............................................................................597
					Fault Codes and Warning Data..................................................................597
					Engine Operation..............................................................................598
					Total Payload and Total Number of Cycles......................................................598
					Other Data....................................................................................598
				OPERATOR FUNCTIONS................................................................................599
					Using the Operator Load Counter...............................................................599
					Viewing the Operator Load Counter.............................................................599
					Clearing the Operator Load Counter............................................................599
					Dimming the Lights on the Display.............................................................599
				INITIAL SETUP OF PAYLOAD METER....................................................................600
					Switch Settings...............................................................................600
					Checking the Operator Check Mode..............................................................601
					Checking the Service Check Mode...............................................................601
					Checking the Gt setting:......................................................................602
					Checking the Inclinometer Settings............................................................602
					Calibrating a Truck...........................................................................602
				DISPLAYS AT START-UP..............................................................................603
					Normal Operation..............................................................................603
				SETUP AND MAINTENANCE.............................................................................604
					Setting The Speed Limit.......................................................................604
					Setting the Option Code.......................................................................604
					Setting The Machine I.D. Code.................................................................605
					Setting The Operator I.D. Code................................................................605
					Setting The Time and Date.....................................................................605
				DOWNLOAD OF INFORMATION...........................................................................606
				DISPLAY OF FAULT CODES............................................................................606
					Monitoring Input Signals......................................................................610
					Service Check Mode............................................................................610
				UP FACTOR - PAYLOAD CALCULATION GAIN..............................................................611
				PL MODE -LOAD CALCULATION TIMING..................................................................611
				FINAL GEAR RATIO SELECTION........................................................................612
				BATTERY REPLACEMENT PROCEDURE.....................................................................613
					Replacing the Battery.........................................................................613
					After Replacing the Battery...................................................................614
				SUSPENSION PRESSURE SENSOR........................................................................614
					Removal.......................................................................................614
					Installation..................................................................................615
				INCLINOMETER......................................................................................615
					Removal.......................................................................................615
					Installation..................................................................................615
					Adjustment....................................................................................615
				PAYLOAD METER BACK PANEL..........................................................................616
				CONNECTIONS.......................................................................................617
				PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE.....................................................618
				PAYLOAD CIRCUIT NUMBERS...........................................................................619
				TROUBLESHOOTING...................................................................................620
					COMMON PROBLEMS...............................................................................620
					Suspension Charging...........................................................................620
					Symptom Table.................................................................................621
					Missing Body-Up Signal........................................................................621
					Missing Speed Signal..........................................................................622
					F-18: Alternator R-Terminal, Oil Pressure Signals.............................................622
					Shorted 18v Sensor Power Supply (930E)........................................................622
				FAULT TREE DIAGNOSIS..............................................................................623
					Payload Lights Won't Illuminate...............................................................623
					Red, Amber or Green Payload Light Does Not Illuminate.........................................624
					Cannot Download - PC Communications...........................................................625
					PC Communications Configuration...............................................................626
					F.CAL: Payload Meter Won't Calibrate..........................................................627
					F-20: Sensor Power Fault......................................................................628
					F-21, F-25: Left Front Pressure Sensor........................................................630
					F-22, F-26: Right Front Pressure Sensor.......................................................630
					F-23, F-27: Left Rear Pressure Sensor.........................................................630
					F-24, F-28: Right Rear Pressure Sensor........................................................630
					F-31, F-32: Inclinometer......................................................................632
					Body Up Input.................................................................................634
					Brake Lock Input..............................................................................635
					Speed Signal..................................................................................636
					Adjusting the Speed Sensor....................................................................636
				CONNECTORS AND PRESSURE SENSORS...................................................................638
				REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM.......................................................641
					Menu Functions................................................................................644
					Using Scope...................................................................................644
					Log File Information..........................................................................644
					Connections to Payload Meter II™..............................................................645
				USING SCOPE.......................................................................................646
					Monitoring Inputs Using Scope.................................................................646
					Monitoring Suspension Charging Using Scope....................................................646
					Pressure Sensor Dummy Loads...................................................................649
				GAIN ADJUSTMENT WORKSHEET.........................................................................650
SECTION N - OPERATOR'S CAB........................................................................................651
	OPERATOR'S CAB INDEX..........................................................................................651
		OPERATOR'S CAB INDEX......................................................................................651
			TRUCK CAB.............................................................................................653
				Description.......................................................................................653
				Removal...........................................................................................654
				Installation......................................................................................655
			CAB DOOR..............................................................................................656
				Removal...........................................................................................656
				Installation......................................................................................656
				Door Adjustment...................................................................................656
				Door Jamb Bolt Adjustment.........................................................................656
				Door Handle Plunger Adjustment....................................................................658
				Replace Door Glass................................................................................659
				Replace Door Window Regulator.....................................................................663
				Replace Door Handle or Latch Assembly.............................................................663
				Door and Door Hinge Seal Replacement..............................................................664
				Door Opening Seal Removal.........................................................................664
				Installation......................................................................................664
			GLASS REPLACEMENT.....................................................................................665
			ADHESIVE-BONDED WINDOWS...............................................................................665
				Replacement Procedure.............................................................................665
			WINDSHIELD & REAR GLASS...............................................................................666
				Removal...........................................................................................666
				Installation......................................................................................667
			CAB COMPONENTS........................................................................................669
			WINDSHIELD WIPER......................................................................................669
				Removal...........................................................................................669
				Installation......................................................................................669
			WINDSHIELD WASHER.....................................................................................670
				Operation.........................................................................................670
				Service...........................................................................................670
			OPERATOR COMFORT......................................................................................671
			HEATER/AIR CONDITIONER................................................................................672
			OPERATION.............................................................................................672
			HEATER COMPONENTS.....................................................................................673
			CIRCUIT BREAKERS......................................................................................673
			HEATER WATER CONTROL SOLENOID.........................................................................673
				Test..............................................................................................674
			HEATER COIL...........................................................................................674
			FAN MOTOR AND SPEED CONTROL...........................................................................675
				Test..............................................................................................675
			ACTUATORS.............................................................................................675
				Test..............................................................................................675
			FILTER................................................................................................675
				Service...........................................................................................675
			AIR CONDITIONER COMPONENTS............................................................................675
SECTION P - LUBRICATION AND SERVICE...............................................................................703
	LUBRICATION AND SERVICE INDEX.................................................................................703
		MOTORIZED WHEEL MAINTENANCE SCHEDULE......................................................................723
		AXLE BOX..................................................................................................723
		MOTORIZED WHEEL MAINTENANCE SCHEDULE......................................................................724
		ARMATURE AREA.............................................................................................724
		AT TIRE CHANGE - FOR ALL MOTORIZED WHEELS.................................................................724
		MOTORIZED WHEEL MAINTENANCE SCHEDULE......................................................................725
		GENERATOR / ALTERNATOR....................................................................................725
		GRID BLOWER MOTOR.........................................................................................725
		CONTROL EQUIPMENT CHECKS..................................................................................725
		MOTORIZED WHEEL MAINTENANCE SCHEDULE......................................................................726
		AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM............................................................726
		VEHICLE OPERATIONS TESTS..................................................................................726
SECTION Q - ALPHABETICAL INDEX....................................................................................727
	ALPHABETICAL INDEX............................................................................................727
SECTION R - SYSTEM SCHEMATICS.....................................................................................731
	SYSTEM SCHEMATICS INDEX.......................................................................................731

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• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
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