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KOMATSU 930E-2 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30121 – A30155 w/CUMMINS QSK-60 Engine) KOMATSU 930E-2 – PDF DOWNLOAD
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- KOMATSU 930E-2 DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30121 – A30155 w/CUMMINS QSK-60 Engine
- PUBLICATION NUMBER:CEBM010401
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KOMATSU 930E-2 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30121 – A30155 w/CUMMINS QSK-60 Engine) KOMATSU 930E-2
KOMATSU 930E-2 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30121 – A30155 W/CUMMINS QSK-60 ENGINE) KOMATSU 930E-2 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-2 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30121 – A30155 w/CUMMINS QSK-60 Engine) KOMATSU 930E-2
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit.
- The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque.
- All torque specifications have æ10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 930E-2 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30121 – A30155 w/CUMMINS QSK-60 Engine) KOMATSU 930E-2
MAIN MENU................................................................................. 0 COVER..................................................................................... 1 FOREWORD.................................................................................. 4 TABLE OF CONTENTS......................................................................... 6 SECTION A -GENERAL INFORMATION ........................................................... 8 SECTION A2 - MAJOR COMPONENT DESCRIPTION.............................................. 10 SECTION A3 - GENERAL SAFETY AND OPERATING INSTRUCTIONS - INDEX........................ 14 GENERAL SAFETY.................................................................... 16 Safety Rules.................................................................. 16 Truck Safety Features......................................................... 16 Clothing And Personal Items................................................... 16 Unauthorized Modification..................................................... 16 Leaving The Operator’s Seat................................................... 16 Mounting And Dismounting...................................................... 16 Fire Extinguishers And First Aid Kits......................................... 17 Precautions For High Temperature Fluids....................................... 17 Asbestos Dust Hazard Prevention............................................... 17 Fire Prevention For Fuel And Oil.............................................. 17 ROPS Precautions.............................................................. 18 Preventing Injury From Work Equipment......................................... 18 Precautions For Optional Attachments.......................................... 18 Precautions When Starting The Machine......................................... 18 PRECAUTIONS FOR TRUCK OPERATION............................................... 19 Safety Is Thinking Ahead.................................................. 19 Safety At The Worksite.................................................... 19 Fire Prevention........................................................... 19 Preparing For Operation................................................... 19 Ventilation For Enclosed Areas............................................ 19 Mirrors, Windows, And Lights.............................................. 19 In The Operator’s Cab - Before Starting The Engine........................ 20 OPERATING THE MACHINE......................................................... 20 Starting The Engine....................................................... 20 Truck Operation - General................................................. 20 Traveling In The Truck.................................................... 21 Precautions When Traveling In Reverse..................................... 21 Traveling On Slopes....................................................... 21 Ensuring Good Visibility.................................................. 22 Operating On Snow......................................................... 22 Avoid Damage To The Dump Body............................................. 22 Driving Near High Voltage Cables.......................................... 22 When Loading The Truck.................................................... 22 When Dumping.............................................................. 22 Working On Loose Ground................................................... 22 Parking The Machine....................................................... 23 TOWING........................................................................ 23 WORKING NEAR BATTERIES........................................................ 23 Jump Starting With Booster Cables......................................... 23 PRECAUTIONS FOR MAINTENANCE....................................................... 24 BEFORE PERFORMING MAINTENANCE................................................. 24 Stopping The Engine Before Service........................................ 24 Warning Tag............................................................... 24 Proper Tools.............................................................. 24 Securing The Dump Body.................................................... 24 DURING MAINTENANCE............................................................ 25 Personnel................................................................. 25 Attachments............................................................... 25 Working Under The Machine................................................. 25 Keeping The Machine Clean................................................. 25 Rules To Follow When Adding Fuel Or Oil................................... 25 Radiator Coolant Level.................................................... 25 Use Of Lighting........................................................... 25 Precautions With The Battery.............................................. 26 Handling High Pressure Hoses.............................................. 26 Precautions With High Pressure Oil........................................ 26 Maintenance Near High Temperatures And High Pressures..................... 26 Rotating Fan And Belts.................................................... 26 Waste Materials........................................................... 26 TIRES......................................................................... 27 Handling Tires............................................................ 27 Storing Tires After Removal............................................... 27 ADDITIONAL JOB SITE RULES......................................................... 28 WHEN REPAIRS ARE NECESSARY........................................................ 29 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK................................... 30 Preliminary Procedures before Welding or Performing Maintenance............... 30 Normal Engine Shutdown Procedure.............................................. 30 Engine Shutdown Procedure before Welding or Performing Maintenance............ 30 TRUCK OPERATION................................................................... 33 PREPARING FOR OPERATION....................................................... 33 Safety Is Thinking Ahead.................................................. 33 WALK AROUND INSPECTION........................................................ 33 ENGINE START-UP SAFETY PRACTICES.............................................. 37 AFTER STARTING THE ENGINE..................................................... 38 Additional Guidelines..................................................... 38 MACHINE OPERATION SAFETY PRECAUTIONS.......................................... 38 MACHINE OPERATION ON THE HAUL ROAD............................................ 39 DYNAMIC RETARDING OPERATION................................................... 40 Dynamic Retarder Control Lever............................................ 40 Dynamic Retarder/Service Brake Pedal...................................... 40 STARTING ON A GRADE WITH A LOADED TRUCK....................................... 41 PASSING....................................................................... 41 LOADING....................................................................... 41 DUMPING....................................................................... 41 Raising The Dump Body..................................................... 41 Lowering The Dump Body.................................................... 42 TOWING........................................................................ 43 SAFE PARKING PROCEDURES....................................................... 44 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................. 44 DELAYED ENGINE SHUTDOWN PROCEDURE............................................. 44 SUDDEN LOSS OF ENGINE POWER................................................... 45 SECTION A4 - WARNINGS AND CAUTIONS.................................................... 46 SECTION A5 - STANDARD CHARTS AND TABLES............................................... 54 SECTION A7............................................................................ 60 STORAGE AND IDLE MACHINE PREPARATION.............................................. 62 Short Term Idle Periods....................................................... 62 PREPARATION FOR STORAGE....................................................... 63 REMOVAL FROM STORAGE.......................................................... 64 RECONDITIONING AN IDLE VEHICLE................................................ 66 ENGINE OPERATION.............................................................. 69 After The Engine Has Started.............................................. 70 ENGINE STORAGE................................................................ 71 Preparing Engine For Storage.............................................. 71 Temporary Storage (30 Days Or Less)....................................... 71 Extended Storage (more Than 30 Days)...................................... 71 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................... 73 ELECTRIC DRIVE TRUCKS......................................................... 74 Storage Instructions and Procedures....................................... 74 Placing Equipment Into Storage............................................ 74 Storing A Truck That Is Operational....................................... 74 Storing A Truck That Is Not Operational................................... 75 Storing A Major Component................................................. 75 Periodic Inspections...................................................... 76 Placing Equipment Into Service After Storage.............................. 76 When A Truck Is Operational............................................... 76 When A Truck Is Not Operational........................................... 76 For The First Hour........................................................ 77 SECTION B................................................................. 78 SECTION B - STRUCTURES.................................................................... 78 SECTION B2 - STRUCTURAL COMPONENTS - INDEX............................................ 80 STRUCTURAL COMPONENTS............................................................. 82 Preparation................................................................... 82 GRILLE, HOOD AND LADDER....................................................... 83 Removal................................................................... 83 Installation.............................................................. 83 DECKS......................................................................... 84 RIGHT DECK AND COMPONENTS..................................................... 84 Removal................................................................... 84 Installation.............................................................. 85 LEFT DECK..................................................................... 85 Removal................................................................... 85 Installation.............................................................. 85 CENTER DECK................................................................... 85 SECTION B3 - DUMP BODY - INDEX........................................................ 86 DUMP BODY......................................................................... 88 Removal....................................................................... 88 Installation.................................................................. 89 BODY PADS..................................................................... 90 Adjustment................................................................ 90 BODY GUIDE.................................................................... 91 HOIST LIMIT SWITCH............................................................ 91 BODY UP SWITCH................................................................ 91 BODY-UP RETENTION CABLE....................................................... 91 ROCK EJECTORS................................................................. 92 Rock Ejectors (Type I)........................................................ 92 Inspection................................................................ 92 Rock Ejectors (Type II)....................................................... 93 Inspection................................................................ 93 SECTION B4 - FUEL TANK - INDEX........................................................ 94 FUEL TANK......................................................................... 96 Removal....................................................................... 97 Installation.................................................................. 97 Repair........................................................................ 97 Cleaning...................................................................... 97 FUEL GAUGE SENDER............................................................. 98 Removal................................................................... 98 Installation.............................................................. 98 LOW FUEL SWITCH............................................................... 98 WIGGINS QUICK FILL FUEL SYSTEM.................................................... 99 FUEL RECEIVER................................................................. 99 TANK BREATHER VALVE........................................................... 99 Removal................................................................... 99 Installation.............................................................. 99 Disassembly............................................................... 99 Assembly.................................................................. 99 LEFT SIDE FILL................................................................100 SECTION C.................................................................102 ENGINE....................................................................102 INDEX.....................................................................102 SECTION C - ENGINE - INDEX................................................................102 SECTION C2 - POWER MODULE - INDEX.....................................................104 POWER MODULE......................................................................106 Preparation...................................................................106 Preparation for Removal.......................................................107 Removal - Power Module........................................................110 Installation - Power Module...................................................112 Hookup - Power Module.........................................................112 SECTION C3 - COOLING SYSTEM - INDEX...................................................114 COOLING SYSTEM....................................................................116 RADIATOR......................................................................116 Removal - Radiator........................................................116 RADIATOR REPAIR...............................................................118 Internal Inspection.......................................................118 External Cleaning.........................................................118 Disassembly...............................................................119 Cleaning and Inspection...................................................120 Assembly..................................................................120 Pressure Testing..........................................................121 Additional Service Information............................................121 Installation - Radiator...................................................122 RADIATOR FILLING PROCEDURE....................................................123 COOLANT SYSTEM TROUBLESHOOTING................................................123 SECTION C4 - POWERTRAIN - INDEX.......................................................124 POWER TRAIN.......................................................................126 ALTERNATOR....................................................................126 Removal - Alternator......................................................126 ENGINE/ALTERNATOR MATING......................................................128 General Instructions......................................................128 Measuring Procedure.......................................................128 Joining The Alternator and Engine.........................................130 ENGINE........................................................................131 Removal...................................................................131 Service...................................................................131 Installation..............................................................131 SECTION C5 - AIR CLEANERS - INDEX.....................................................132 AIR CLEANERS......................................................................134 AIR CLEANERS..................................................................134 Operation.................................................................134 General Service Information...............................................134 FILTER ELEMENT REPLACEMENT....................................................135 Main Filter Element Cleaning..............................................136 Precleaner Section........................................................137 Cleaning Precleaner Tubes.................................................137 AIR INTAKE TROUBLESHOOTING....................................................138 SECTION D.................................................................174 ELECTRICAL SYSTEM (24VDC NON-PROPULSION)..................................174 INDEX.....................................................................174 SECTION C7 - FAN CLUTCH - INDEX.......................................................140 FAN CLUTCH........................................................................142 REMOVAL AND INSTALLATION TOOLING..............................................142 FAN CLUTCH - DISASSEMBLY......................................................145 CLEANING AND INSPECTION.......................................................155 ASSEMBLY - FAN CLUTCH.........................................................159 TEST PROCEDURE................................................................173 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX..............................174 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX.....................................176 24VDC ELECTRIC SUPPLY SYSTEM......................................................178 ELECTRICAL SYSTEM DESCRIPTION.................................................178 BATTERIES.....................................................................178 Maintenance and Service...................................................178 Troubleshooting...........................................................178 BATTERY SUPPLY SYSTEM.........................................................180 24VDC Battery Charging Alternator.........................................180 Battery Box...............................................................180 Battery Control Box.......................................................180 System Battery Starter Disconnect Relay...................................180 Battery Disconnect Switches...............................................181 24VDC Auxiliary Battery Connectors........................................181 Battery Equalizer.........................................................182 Troubleshooting...........................................................182 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX...............................184 24 VDC ELECTRICAL SYSTEM COMPONENTS...............................................186 PASSENGER SEAT BASE COMPARTMENT...............................................186 TRUCK SHUTDOWN PROCEDURE......................................................186 COMPONENTS....................................................................186 Tail Light Resistor Diode Assemblies......................................186 5 Minute Idle Timer Components............................................186 Inclinometer..............................................................188 Brake Warning Buzzer (BWB)................................................188 Alarm Indicating Device (AID) System......................................188 ELECTRICAL INTERFACE CABINET..................................................191 Lubrication System Timer..................................................191 Barometric Pressure Transducer............................................191 Special Interface Module..................................................191 Power Distribution Terminals..............................................191 Truck Control Interface Panel.............................................191 Control Power Relay.......................................................191 Circuit Breaker Panel.....................................................191 Diode Board - DB1.........................................................193 Diode Testing.............................................................193 RELAY BOARDS..................................................................194 Relay Boards - RB1, RB2, RB3, RB4, RB5....................................194 Service...................................................................194 Relay Board Identification................................................195 Relay Board Functions.....................................................196 Relay Board 6 (RB6).......................................................197 BODY-UP SWITCH................................................................198 Operation.................................................................198 Adjustment................................................................198 Service...................................................................198 HOIST LIMIT SWITCH............................................................199 Operation.................................................................199 Adjustment................................................................199 Service...................................................................199 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX.....................................202 BATTERY CHARGING ALTERNATOR.......................................................204 ELECTRICAL SYSTEM DESCRIPTION.................................................204 BATTERY.......................................................................204 Maintenance and Service...................................................204 Troubleshooting...........................................................204 BATTERY CHARGING SYSTEM (Niehoff).............................................206 General Description.......................................................206 TROUBLESHOOTING PROCEDURES (On-Truck).........................................206 Equipment Required:.......................................................206 Preliminary Checks........................................................207 Test Setup................................................................207 Test Procedure............................................................207 Regulator Bypass Test.....................................................208 ON VEHICLE TROUBLESHOOTING GUIDE..................................................210 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage....210 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:..............................210 CHARGE VOLT AND AMP VALUES....................................................211 DEFINITIONS...................................................................211 ADVANCED SYSTEM TROUBLESHOOTING...................................................212 Static Test - Engine OFF, Key ON, Battery Switch ON...........................212 Go To Alternator..............................................................212 Go To Regulator (If Required).................................................213 Go To Regulator Connector On The Alternator...................................213 ALTERNATOR OVERHAUL...............................................................214 ALTERNATOR DIMENSIONS.........................................................214 ALTERNATOR SPECIFICATIONS.....................................................215 SERVICE PARTS.................................................................216 ON-VEHICLE TEST...............................................................218 Equipment:................................................................218 Preliminary Checks:.......................................................218 Test Set-up...............................................................218 Test Procedure............................................................218 ON-VEHICLE TEST...............................................................219 Bypass Test:..............................................................219 BENCH TEST....................................................................220 STATIC TESTS..................................................................221 Regulator Tests...........................................................221 Control Box Tests.........................................................222 ALTERNATOR DISASSEMBLY........................................................224 ASSEMBLY- ALTERNATOR..........................................................229 BF4822 STATOR SERVICE TOOL INSTRUCTIONS...........................................238 Stator Removal And Replacement................................................238 Stator Installation...........................................................239 SECTION E.....................................................................242 ELECTRICAL PROPULSION SYSTEM..................................................242 INDEX.........................................................................242 SECTION E - ELECTRICAL PROPULSION SYSTEM - INDEX..........................................242 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX..........................244 ELECTRICAL PROPULSION SYSTEM COMPONENTS...........................................246 GENERAL SYSTEM DESCRIPTION....................................................246 SYSTEM COMPONENTS.............................................................248 Auxiliary Blower System...................................................248 Propulsion System Controller (PSC)........................................248 TRUCK CONTROL INTERFACE PANEL (TCI)...........................................249 Diagnostic Information Display............................................250 DID PANEL EVENT CODES.........................................................250 PSC SOFTWARE FUNCTIONS........................................................275 Input Processing..........................................................275 STATE MANAGEMENT..............................................................275 State Machine.............................................................275 Transitions Between States................................................276 DC Link State.............................................................278 Powering the Link.........................................................278 De-Powering the Link......................................................278 Control Functions.........................................................278 Engine Control............................................................278 ALTERNATOR FIELD CONTROL......................................................279 Desired Three-Phase Voltage...............................................279 Desired DC Link Voltage...................................................279 Self-load.................................................................279 Propel Torque Control.....................................................280 Retard Torque Control.....................................................280 Wheel Slide Control.......................................................280 Resistor Grid Control.....................................................281 Chopper Voltage Control...................................................281 AUXILIARY BLOWER CONTROL......................................................281 EVENT PROCESSING..............................................................281 Event Detection...........................................................281 Power On Tests............................................................281 Initiated Tests...........................................................282 Periodic Tests............................................................282 EVENT RESTRICTIONS............................................................282 EVENT LOGGING AND STORAGE.....................................................282 Event History Buffer......................................................283 Data Packs................................................................283 To Record and Save a Data Pack to a Floppy Disk...........................283 Event Reset...............................................................284 SERIAL DATA COMMUNICATIONS....................................................285 PSC - TCI Communications processing.......................................285 PSC - PTU Communications Processing.......................................285 Inverter Communications Processing........................................285 OUTPUT PROCESSING.............................................................286 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS......................................286 Fast Start................................................................286 Engine Shutdown/Engine Not Running........................................286 Limp Home Mode............................................................286 Entering/Exiting Limp Home Mode...........................................286 PROPULSION SYSTEM COMPONENT ABBREVIATIONS.....................................287 ELECTRONIC ACCELERATOR AND RETARD PEDALS......................................297 Removal...................................................................297 Installation..............................................................297 Disassembly...............................................................297 Assembly..................................................................297 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE - INDEX....................298 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.....................................300 AC DRIVE SYSTEM MAINTENANCE...................................................300 TRUCK SHUTDOWN PROCEDURES.....................................................300 NORMAL TRUCK SHUTDOWN PROCEDURE...............................................301 SHUTDOWN AFTER SYSTEM FAILURE.................................................302 SYSTEM CHECKOUT...............................................................303 Battery and Control Checks of System WITH Battery Power OFF...............303 Battery and Control Circuit Checks of System With Battery Power ON........306 Checks with Key Switch OFF................................................307 CPU Battery Checks........................................................309 MEMORY BACKUP BATTERY REPLACEMENT.............................................309 TCI PROGRAMMING...............................................................310 PSC PROGRAMMING...............................................................310 INVERTER PROGRAMMING..........................................................311 TCI CHECKOUT..................................................................311 Modular Mining Communication Port.........................................312 TCI Input Checks..........................................................313 TCI Digital Output Tests..................................................315 TCI Digital Input Tests...................................................317 PSC Checkout Procedure....................................................319 PSC Digital Input Checks..................................................323 Miscellaneous Checks......................................................324 A3PV Panel................................................................324 LINKV Panel...............................................................324 Thermistor Checks.........................................................324 17FM384 Panel Check.......................................................324 Pedal Percentages and Meter Calibration...................................325 Meter Calibration Procedure...............................................325 Reprogram With Serial Numbers and Pedal Percentages.......................327 LOAD TESTING..................................................................329 Preload Checks............................................................329 ADDITIONAL TRUCK CHECKS.......................................................331 On-Board Load Testing.....................................................333 Preparation...............................................................333 Initiate Loadbox Test.....................................................336 Manual Offset HP Output Adjustment........................................338 TROUBLESHOOTING...................................................................340 PVM Optimum Load Curve Handshaking Troubleshooting............................340 MISCELLANEOUS COMPONENT REPAIR................................................341 Troubleshooting Phase Modules and Chopper Modules.........................341 Phase Module Removal and Snubber Resistor Replacement.....................341 Snubber Resistor Installation.............................................342 Phase Module Installation.................................................342 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING..............................343 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING..............................346 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING......................................347 IGBT TROUBLESHOOTING..........................................................348 SECTION G.................................................................350 REAR AXLE, SPINDLES AND WHEELS............................................350 INDEX.....................................................................350 SECTION G - REAR AXLE, SPINDLES AND WHEELS - INDEX........................................350 SECTION G2 - TIRES AND RIMS - INDEX...................................................352 TIRES AND RIMS....................................................................354 WHEEL STUD MAINTENANCE........................................................355 FRONT TIRES AND RIMS..........................................................356 Removal...................................................................356 Installation..............................................................357 REAR TIRES AND RIMS...........................................................358 Removal...................................................................358 Installation..............................................................359 RIM...........................................................................360 Tire Removal..............................................................360 Tire Installation.........................................................361 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX......................................364 FRONT WHEEL HUB AND SPINDLE.......................................................366 WHEEL HUB AND SPINDLE ASSEMBLY................................................366 Preparation...............................................................366 Removal...................................................................366 Installation - Wheel Hub and Spindle Assembly.............................369 Disassembly - Wheel Hub and Spindle Assembly..............................370 Cleaning and Inspection - Wheel Hub and Spindle Assembly..................370 Assembly - Wheel Hub and Spindle Assembly.................................372 Wheel Bearing Adjustment:.................................................372 Brake Installation........................................................373 Seal Assembly Gap Check...................................................374 STEERING CYLINDERS AND TIE ROD................................................375 Spherical Bearing Wear Limits.............................................375 Removal - Steering Cylinder and Tie Rod...................................376 Installation - Steering Cylinder and Tie Rod..............................377 Bearing Replacement.......................................................377 TOE-IN ADJUSTMENT.............................................................378 SECTION G4 - REAR AXLE HOUSING - INDEX................................................380 REAR AXLE HOUSING ATTACHMENT......................................................382 PIVOT PIN.....................................................................382 Removal...................................................................382 Installation..............................................................382 PIVOT EYE BEARING.............................................................383 Disassembly...............................................................383 Assembly..................................................................383 PIVOT EYE REPAIR..............................................................384 Removal...................................................................384 Disassembly...............................................................384 Assembly..................................................................384 Installation..............................................................384 ANTI-SWAY BAR.................................................................385 Removal...................................................................385 Installation..............................................................385 Disassembly...............................................................385 Cleaning and Inspection...................................................385 Assembly..................................................................385 SECTION G5 - REAR AXLE HOUSING - INDEX................................................386 REAR AXLE HOUSING.................................................................388 REAR AXLE HOUSING.............................................................388 Preparation...............................................................388 Removal...................................................................388 Cleaning and Inspection - Rear Axle Housing...............................390 Installation - Rear Axle Housing..........................................390 WHEEL MOTOR...................................................................391 Preparation...............................................................391 Removal...................................................................391 Cleaning and Inspection - Wheel Motor.....................................392 Installation - Wheel Motor................................................393 WHEEL MOTOR GEAR OIL..........................................................396 Filtering Requirements....................................................396 Particle Size Analysis....................................................396 Flushing..................................................................396 Oil Sample Analysis.......................................................397 ELEMENT SPECIFICATION CHARTS..................................................398 SECTION H.................................................................402 HYDRAIR® II SUSPENSIONS...................................................402 INDEX.....................................................................402 SECTION H - HYDRAIR II SUSPENSIONS - INDEX................................................402 SECTION H2 - FRONT SUSPENSIONS - INDEX................................................404 FRONT SUSPENSION..................................................................406 Removal.......................................................................406 Installation - Front Suspension...............................................407 "Turn-Of-The-Nut" Tightening Procedure........................................410 MINOR REPAIRS (LOWER BEARING & SEALS).........................................411 Removal - Bearing Retainer................................................411 Installation - Bearing Retainer...........................................411 MAJOR SUSPENSION REBUILD......................................................413 Disassembly...............................................................413 Assembly..................................................................413 SECTION H3 - REAR SUSPENSIONS - INDEX.................................................416 REAR SUSPENSIONS..................................................................418 Removal.......................................................................418 Installation - Rear Suspension................................................420 Disassembly - Rear Suspension.................................................421 Cleaning and Inspection - Rear Suspension.....................................421 Assembly - Rear Suspension....................................................421 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX.........................424 SUSPENSION OILING AND CHARGING PROCEDURE..........................................426 GENERAL.......................................................................426 EQUIPMENT LIST................................................................426 Hydrair® Charging Kit.....................................................426 Installation of Charging Kit..............................................426 Removal of Charging Kit...................................................427 Support Blocks For Oiling And Charging Dimensions.........................427 FRONT SUSPENSION..............................................................428 Front Suspension Oiling...................................................428 Front Suspension Nitrogen Charging........................................429 REAR SUSPENSION...............................................................430 Rear Suspension Oiling....................................................430 Rear Suspension Nitrogen Charging.........................................431 OIL AND NITROGEN SPECIFICATIONS CHART.............................................433 SECTION J.....................................................................434 BRAKE CIRCUIT.................................................................434 INDEX.........................................................................434 SECTION J - BRAKE CIRCUIT - INDEX.........................................................434 SECTION J2 - BRAKE CIRCUIT - INDEX....................................................436 BRAKE CIRCUIT.....................................................................438 SERVICE BRAKE CIRCUIT.........................................................438 SECONDARY BRAKING AND AUTOMATIC APPLY.........................................440 PARKING BRAKE CIRCUIT.........................................................440 BRAKE LOCK CIRCUIT............................................................441 WARNING CIRCUIT...............................................................441 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX..................................444 BRAKE CIRCUIT COMPONENT SERVICE...................................................446 BRAKE VALVE...................................................................446 Rebuild Criteria..........................................................446 Removal - Brake Valve.....................................................447 Installation - Brake Valve................................................447 Disassembly - Brake Valve.................................................448 Cleaning and Inspection - Brake Valve.....................................451 Assembly - Actuator Base Threaded Inserts.................................451 Assembly - Boot and Cap...................................................451 Installation - Valve Body Seal............................................451 Installation - Regulator Sleeve O-Ring....................................452 Installation - Actuator Plunger O-ring....................................452 Assembly - Brake Valve....................................................452 DIFFERENTIAL PRESSURE SWITCH..................................................454 Disassembly...............................................................454 Cleaning and Inspection...................................................454 Assembly..................................................................454 VALVE BENCH TEST AND ADJUSTMENT...............................................455 Test Set Up Procedure.....................................................456 Adjustment - Brake Valve Output Pressure..................................456 Adjustment - Differential Pressure Switch.................................456 Final Test and Adjustment.................................................457 Installation - Brake Pedal Actuator Assembly to Brake Valve...............458 Installation - Retard Pedal To Brake Pedal................................458 DUAL RELAY VALVE..............................................................460 Removal...................................................................460 Installation..............................................................460 Disassembly - Dual Relay Valve............................................462 Cleaning and Inspection - Dual Relay Valve................................462 Assembly - Dual Relay Valve...............................................462 DIFFERENTIAL PRESSURE SWITCH..................................................463 Disassembly...............................................................463 Cleaning and Inspection...................................................463 Assembly..................................................................463 VALVE TEST AND ADJUSTMENT.....................................................464 Test Set Up Procedure.....................................................465 Adjustment - Brake Valve Output Pressure..................................465 Adjustment - Differential Pressure Switch.................................466 BRAKE MANIFOLD................................................................467 Removal...................................................................467 Installation..............................................................468 Disassembly...............................................................468 Cleaning and Inspection...................................................468 Assembly..................................................................468 HYDRAULIC BRAKE ACCUMULATORS..................................................469 Brake Accumulator Bleed Down Procedure....................................469 ACCUMULATORS - HYDRAULIC COMPONENT CABINET....................................469 Removal...................................................................469 Installation..............................................................469 Disassembly...............................................................469 Cleaning and Inspection...................................................471 Assembly..................................................................471 BLADDER ACCUMULATOR CHARGING PROCEDURE........................................473 Temperature During Precharge..............................................474 Precharge Maintenance.....................................................474 Accumulator Storage Procedures............................................475 Bladder Storage Procedures................................................476 ACCUMULATORS - FRAME MOUNTED..................................................476 Removal...................................................................476 Installation..............................................................476 Disassembly...............................................................478 Cleaning and Inspection...................................................478 Assembly - Accumulator....................................................479 Accumulator Testing.......................................................479 ACCUMULATOR CHARGING PROCEDURE................................................480 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)..............................481 Removal - Retarder Control Lever..........................................481 Installation - Retarder Control Lever.....................................481 Disassembly and Adjustment - Retarder Control Lever.......................482 Potentiometer Check - Retarder Control Lever..............................482 Assembly - Retarder Control Lever.........................................482 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX................................484 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................486 EQUIPMENT REQUIRED............................................................488 INITIAL SYSTEM SET-UP.........................................................489 BRAKE SYSTEM CHECKOUT.........................................................490 Failure Modes Check-Out...................................................491 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING.....................................494 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.............................498 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX..........................................500 WET DISC BRAKE ASSEMBLY...........................................................502 OPERATION.....................................................................502 MAINTENANCE...................................................................503 Brake Disc Wear Indicator.................................................503 Removal/Installation - Wet Disc Brake Assembly............................503 BRAKE REBUILD.................................................................505 Disassembly...............................................................505 Cleaning and Inspection...................................................508 Assembly..................................................................509 Floating Ring Seal Assembly/Installation..................................512 WET DISC BRAKE BLEEDING PROCEDURE.............................................515 SECTION J7 - PARKING BRAKE - INDEX....................................................516 PARKING BRAKE.....................................................................518 OPERATION.....................................................................518 MAINTENANCE...................................................................519 Inspection - Parking Brake................................................519 Removal - Parking Brake...................................................519 Installation - Parking Brake..............................................520 Disassembly - Parking Brake...............................................521 Cleaning and Inspection - Parking Brake...................................521 Assembly - Parking Brake..................................................521 PARKING BRAKE BLEEDING PROCEDURE..............................................523 SECTION L.................................................................524 HYDRAULIC SYSTEM..........................................................524 INDEX.....................................................................524 SECTION L - HYDRAULIC SYSTEM - INDEX......................................................524 SECTION L2 - HYDRAULIC SYSTEM - INDEX.................................................526 HYDRAULIC SYSTEM..................................................................528 Hoist Circuit Operation.......................................................529 Steering Circuit Operation....................................................531 Disc Brake Cooling System.....................................................533 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX................................536 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................538 HOIST PUMP....................................................................538 Removal...................................................................538 Installation..............................................................540 Disassembly...............................................................541 Inspection Of Parts.......................................................545 Assembly..................................................................545 TROUBLESHOOTING GUIDE.............................................................550 HYDRAULIC TANK................................................................551 Filling Instructions......................................................551 Removal...................................................................551 Installation..............................................................552 HYDRAULIC TANK STRAINERS......................................................552 Removal...................................................................552 Inspect and Clean.........................................................552 Installation..............................................................552 Hydraulic Tank Breathers..................................................553 SECTION L4 - STEERING CIRCUIT - INDEX.................................................554 STEERING CIRCUIT..................................................................556 STEERING CIRCUIT OPERATION....................................................556 COMPONENT DESCRIPTION.........................................................557 Steering Control Valve....................................................557 Bleeddown Manifold Valve..................................................558 Bleeddown Solenoids.......................................................558 Accumulators..............................................................559 Low Precharge Warning Switch..............................................559 High Pressure Filter......................................................559 Flow Amplifier............................................................559 FLOW AMPLIFIER SYSTEM OPERATION...............................................561 No Steer..................................................................561 Steering Left.............................................................563 Steering Right............................................................565 No Steer, External Shock Load.............................................567 STEERING PUMP.................................................................569 Operation.................................................................569 High Altitude Operation...................................................569 PRINCIPLE OF OPERATION........................................................571 Steering Pump.............................................................572 SECTION L5 - STEERING CONTROL UNIT - INDEX............................................574 STEERING CONTROL UNIT.............................................................576 Removal.......................................................................576 Installation..................................................................576 STEERING CONTROL UNIT REBUILD.................................................577 Disassembly...............................................................577 Cleaning and Inspection - Steering Control Unit...........................578 Assembly - Steering Control Unit..........................................580 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX................................584 STEERING CIRCUIT COMPONENT REPAIR.................................................586 BLEEDDOWN MANIFOLD VALVE......................................................586 Removal...................................................................586 Installation..............................................................586 ACCUMULATORS..................................................................587 Removal...................................................................587 Installation..............................................................587 Disassembly...............................................................588 Cleaning and Inspection...................................................588 Assembly..................................................................589 TESTING...................................................................589 STEERING ACCUMULATOR CHARGING PROCEDURE.......................................590 FLOW AMPLIFIER............................................................591 Removal...................................................................591 Installation..............................................................591 FLOW AMPLIFIER REBUILD....................................................591 Disassembly...............................................................593 Assembly..................................................................594 STEERING CYLINDERS............................................................595 Disassembly...............................................................596 Piston Seal & Bearing Installation........................................596 Cylinder Assembly.........................................................596 Test......................................................................596 STEERING AND BRAKE PUMP.......................................................597 Removal...................................................................597 Installation..............................................................597 Disassembly...................................................................599 Control Piston Group......................................................599 Valve Plate Group.........................................................599 Rotating Group............................................................602 Swashblock Group..........................................................602 Driveshaft Group..........................................................602 Inspection....................................................................602 Control Piston Group......................................................602 Valve Plate Group.........................................................602 Rotating Group............................................................602 Swashblock Group..........................................................604 Driveshaft Group..........................................................605 Compensator Block and Unloader Module.....................................605 Stroke Adjuster Assembly..................................................605 Assembly......................................................................605 Swashblock Group..........................................................605 Driveshaft Group..........................................................606 Rotating Group............................................................606 Control Piston Group......................................................606 Valve Plate Group.........................................................607 TROUBLESHOOTING CHART.............................................................608 SECTION L7 - HOIST CIRCUIT - INDEX....................................................614 HOIST CIRCUIT.....................................................................616 HOIST CIRCUIT OPERATION.......................................................616 COMPONENT DESCRIPTION.........................................................617 Hydraulic Tank............................................................617 Hydraulic Pump............................................................617 High Pressure Filters.....................................................617 Hoist Valve...............................................................617 Inlet Sections............................................................617 Spool Sections............................................................618 Work Ports (Rear) Spool Section...........................................618 Tank Ports (Front) Spool Section..........................................618 Hoist Pilot Valve.........................................................618 Hoist Up Limit Solenoid...................................................619 Pilot Operated Check Valve................................................619 Snubber Valve.............................................................619 Counterbalance Valve......................................................619 HOIST CIRCUIT OPERATION.......................................................619 POWER UP OPERATION (Figure 7-5)...........................................621 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX...................................630 HOIST CIRCUIT COMPONENT REPAIR....................................................632 HOIST VALVE...................................................................632 Removal...................................................................632 Installation..............................................................633 O-Ring Replacement........................................................633 INLET SECTION.............................................................634 Disassembly...............................................................634 Cleaning and Inspection...................................................635 Assembly..................................................................635 REAR SPOOL SECTION (Work Ports)...........................................635 Disassembly...............................................................635 Cleaning and Inspection...................................................637 Assembly..................................................................637 FRONT SPOOL SECTION (Tank Ports)..........................................638 Disassembly...............................................................638 Cleaning and Inspection...................................................638 Assembly..................................................................638 HOIST PILOT VALVE.............................................................640 Removal...................................................................640 Installation..............................................................640 Disassembly...............................................................641 Cleaning and Inspection...................................................642 Assembly..................................................................642 HOIST - UP LIMIT SOLENOID VALVE...........................................643 HOIST CYLINDERS...............................................................643 Removal...................................................................643 Installation..............................................................644 Disassembly...............................................................646 Cleaning and Inspection...................................................647 ASSEMBLY OF QUILL AND CYLINDER............................................648 Quill Installation........................................................648 Installation Of Check Balls And Plugs In Quill............................649 Assembly of Cylinder......................................................650 DISABLED TRUCK DUMPING PROCEDURE..............................................651 HOOKUP....................................................................651 DUMPING PROCEDURE.........................................................651 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX.........................................652 HYDRAULIC SYSTEM FILTERS..........................................................654 HOIST CIRCUIT FILTER..........................................................654 Filter Element Replacement................................................654 Removal - Hoist Circuit Filter............................................655 Installation - Hoist Circuit Filter.......................................655 Indicator Switch - Hoist Circuit Filter...................................655 STEERING CIRCUIT FILTER.......................................................656 Filter Element Replacement................................................656 Removal - Steering Circuit Filter.........................................657 Installation - Steering Circuit Filter....................................657 Indicator Switch - Steering Circuit Filter................................657 INDICATOR SWITCH..............................................................657 Test Procedure............................................................657 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX...................................660 HYDRAULIC CHECK-OUT PROCEDURE.....................................................662 GENERAL INFORMATION...........................................................662 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.............................662 Equipment Requirements....................................................663 Pump Pressure Control Adjustments.........................................663 Steering Control Valve and Flow Amplifier Leakage Test....................664 Bleeddown Manifold Leakage Test...........................................664 Steering / Brake Pump Stroke Adjustment...................................665 Shock And Suction Valves..................................................666 Equipment Requirements....................................................666 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.................667 Equipment Requirements....................................................667 Pressure Checks...........................................................667 Brake Cooling Circuit Test................................................667 Power Up Relief Pressure Test.............................................668 Adjustment................................................................668 Power Down Relief Pressure Test...........................................669 Adjustment................................................................669 Hoist Counterbalance Valve Adjustment.....................................670 HYDRAULIC SYSTEM FLUSHING PROCEDURE...............................................671 Preparation...................................................................671 Flushing Procedure............................................................671 Filter Element Replacement....................................................672 930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET...............................674 SECTION M.....................................................................676 OPTIONS AND SPECIAL TOOLS.....................................................676 INDEX.........................................................................676 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX.............................................676 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX.............................................678 FIRE CONTROL SYSTEM (MANUAL)......................................................680 Operation.....................................................................680 Inspection and Maintenance....................................................680 Recharging Procedures.........................................................681 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1......................682 Control Module................................................................682 Actuator......................................................................683 Linear Detection Wire.........................................................683 Power Wire....................................................................683 Test Kit......................................................................683 Squib.........................................................................683 Securing the Detection Wire...................................................684 Preliminary Test Before Final Hook-Up.........................................684 Installation Procedure for Squib..............................................686 Placing the Electric Detection & Actuation System Into Service................686 INSPECTION AND MAINTENANCE SCHEDULES..........................................687 Daily.....................................................................687 Normal Maintenance Based On Actual Operating Hours........................687 IN CASE OF FIRE...............................................................688 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM.....................................690 POSSIBLE CAUSES...............................................................690 SUGGESTED CORRECTIVE ACTION...................................................690 TROUBLE: Test Module Light Will Not Illuminate................................690 POSSIBLE CAUSES...............................................................690 SUGGESTED CORRECTIVE ACTION...................................................690 TROUBLE: Test Module Light Will Not Go Out....................................690 POSSIBLE CAUSES...............................................................690 SUGGESTED CORRECTIVE ACTION...................................................690 TROUBLE: Detonated Squib......................................................690 POSSIBLE CAUSES...............................................................690 SUGGESTED CORRECTIVE ACTION...................................................690 SECTION M8 - SPECIAL TOOLS............................................................692 SECTION M20 - PAYLOAD METER II - ON BOARD WEIGHING SYSTEM - INDEX.....................698 GENERAL INFORMATION...............................................................700 Haul Cycles...................................................................700 LIGHTS, SWITCHES AND COMPONENTS...................................................701 TIPS FOR OPERATION................................................................702 EXTERNAL DISPLAY LIGHTS...........................................................702 THEORY OF OPERATION...............................................................703 Basic Description.............................................................703 Inclinometer..................................................................703 Linkage Factor................................................................703 Gain Factor...................................................................704 Brake Lock....................................................................704 Sources of Error..............................................................704 Typical Data From Service Check Mode..........................................704 Example Calculation of Payload................................................705 Viewing Payload Calculation Inputs............................................705 Checking the Gain.............................................................706 Adjusting the Gain............................................................706 TYPES OF DATA STORED..............................................................707 Cycle Data....................................................................707 Engine ON/OFF Data............................................................708 Fault Codes and Warning Data..................................................708 Engine Operation..............................................................709 Total Payload and Total Number of Cycles......................................709 Other Data....................................................................709 OPERATOR FUNCTIONS................................................................710 Using the Operator Load Counter...............................................710 Viewing the Operator Load Counter.............................................710 Clearing the Operator Load Counter............................................710 Dimming the Lights on the Display.............................................710 INITIAL SETUP OF PAYLOAD METER....................................................711 Switch Settings...............................................................711 Checking the Operator Check Mode..............................................712 Checking the Service Check Mode...............................................712 Checking the Gt setting:......................................................713 Checking the Inclinometer Settings............................................713 Calibrating a Truck...........................................................713 DISPLAYS AT START-UP..............................................................714 Normal Operation..............................................................714 SETUP AND MAINTENANCE.............................................................715 Setting The Speed Limit.......................................................715 Setting the Option Code.......................................................715 Setting The Machine I.D. Code.................................................716 Setting The Operator I.D. Code................................................716 Setting The Time and Date.....................................................716 DOWNLOAD OF INFORMATION...........................................................717 DISPLAY OF FAULT CODES............................................................717 Monitoring Input Signals......................................................721 Service Check Mode............................................................721 UP FACTOR - PAYLOAD CALCULATION GAIN..............................................722 PL MODE -LOAD CALCULATION TIMING..................................................722 FINAL GEAR RATIO SELECTION........................................................723 BATTERY REPLACEMENT PROCEDURE.....................................................724 Replacing the Battery.........................................................724 After Replacing the Battery...................................................725 SUSPENSION PRESSURE SENSOR........................................................725 Removal.......................................................................725 Installation..................................................................726 INCLINOMETER......................................................................726 Removal.......................................................................726 Installation..................................................................726 Adjustment....................................................................726 PAYLOAD METER BACK PANEL..........................................................727 CONNECTIONS.......................................................................728 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE.....................................729 PAYLOAD CIRCUIT NUMBERS...........................................................730 TROUBLESHOOTING...................................................................731 COMMON PROBLEMS...............................................................731 Suspension Charging.......................................................731 Symptom Table.............................................................732 Missing Body-Up Signal....................................................732 Missing Speed Signal......................................................733 F-18: Alternator R-Terminal, Oil Pressure Signals.........................733 Shorted 18v Sensor Power Supply (930E)....................................733 FAULT TREE DIAGNOSIS..........................................................734 Payload Lights Won't Illuminate...........................................734 Red, Amber or Green Payload Light Does Not Illuminate.....................735 Cannot Download - PC Communications.......................................736 PC Communications Configuration...........................................737 F.CAL: Payload Meter Won't Calibrate......................................738 F-20: Sensor Power Fault..................................................739 F-21, F-25: Left Front Pressure Sensor....................................741 F-22, F-26: Right Front Pressure Sensor...................................741 F-23, F-27: Left Rear Pressure Sensor.....................................741 F-24, F-28: Right Rear Pressure Sensor....................................741 F-31, F-32: Inclinometer..................................................743 Body Up Input.............................................................745 Brake Lock Input..........................................................746 Speed Signal..............................................................747 Adjusting the Speed Sensor................................................747 CONNECTORS AND PRESSURE SENSORS...............................................749 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM.......................................752 Menu Functions................................................................755 Using Scope...................................................................755 Log File Information..........................................................755 Connections to Payload Meter II™..............................................756 USING SCOPE.......................................................................757 Monitoring Inputs Using Scope.................................................757 Monitoring Suspension Charging Using Scope....................................757 Pressure Sensor Dummy Loads...................................................760 GAIN ADJUSTMENT WORKSHEET.........................................................761 SECTION N.....................................................................762 CAB COMPONENTS................................................................762 INDEX.........................................................................762 SECTION N - CAB COMPONENTS - INDEX........................................................762 SECTION N2 - TRUCK CAB - INDEX........................................................764 TRUCK CAB.........................................................................766 Description...................................................................766 Preparation...................................................................767 Removal - Cab.................................................................767 Installation - Cab............................................................769 CAB DOOR......................................................................769 Removal...................................................................769 Installation..............................................................769 Door Adjustment...........................................................770 Door Jamb Bolt Adjustment.................................................770 Door Handle Plunger Adjustment............................................771 Door Glass Replacement....................................................772 Door Window Regulator Replacement.........................................776 Door Handle or Latch Assembly Replacement.................................776 Door and Door Hinge Seal Replacement......................................777 Door Opening Seal Removal.................................................777 Installation..............................................................777 GLASS REPLACEMENT.............................................................778 Adhesive Bonded Windows...................................................778 Replacement Procedure.....................................................778 Windshield And Rear Glass.................................................779 Removal...................................................................779 Installation..............................................................780 SECTION N3 - CAB COMPONENTS - INDEX...................................................782 CAB COMPONENTS....................................................................784 WINDSHIELD WIPERS.............................................................784 Wiper Motor Replacement...................................................784 Removal...................................................................784 Installation..............................................................784 Wiper Arm Replacement.....................................................784 Removal...................................................................784 Installation..............................................................785 Wiper Linkage Replacement.................................................785 Removal...................................................................785 Installation..............................................................785 WINDSHIELD WASHER.............................................................786 Operation.................................................................786 Service...................................................................786 OPERATOR SEAT.................................................................787 Adjustment................................................................787 Removal...................................................................787 Installation..............................................................787 SECTION N4 - OPERATING COMFORT - INDEX................................................788 OPERATOR COMFORT..................................................................790 HEATER/AIR CONDITIONER........................................................790 Operation.................................................................790 HEATER COMPONENTS.............................................................791 Circuit Breakers..........................................................791 Heater Control Components.................................................791 Heater Coil...............................................................791 Fan Motor And Speed Control...............................................792 Actuators.................................................................792 Filter Service............................................................792 AIR CONDITIONING SYSTEM...........................................................794 Environmental Impact..........................................................794 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.....................................795 PRINCIPLES OF REFRIGERATION...................................................795 Air Conditioning..........................................................795 Refrigeration - The Act Of Cooling........................................796 The Refrigeration Cycle...................................................796 AIR CONDITIONER SYSTEM COMPONENTS.............................................797 Compressor (Refrigerant Pump).............................................797 Service Valves............................................................797 Condenser.................................................................797 Receiver-Drier............................................................797 Expansion Block Valve.....................................................798 Accumulator...............................................................798 Evaporator................................................................798 ELECTRICAL CIRCUIT............................................................799 Thermostat................................................................799 Compressor Clutch.........................................................799 Trinary™ Switch...........................................................800 SYSTEM SERVICING..............................................................801 SERVICE TOOLS AND EQUIPMENT...................................................802 Recovery/Recycle Station..................................................802 Leak Detector.............................................................802 Service Valves............................................................803 Vacuum Pump...............................................................803 Manifold Gauge Set........................................................804 Installing Manifold Gauge Set.............................................805 Purging Air From Service Hoses............................................805 SYSTEM PERFORMANCE TEST.......................................................806 SYSTEM OIL....................................................................807 Handling and Reusing PAG Oil..............................................807 Oil Quantity..............................................................807 Checking System Oil.......................................................807 REFRIGERANT...................................................................808 Recycled Refrigerant......................................................808 Reclaimed Refrigerant.....................................................808 Refrigerant Quantity......................................................808 R-134a Refrigerant Containers.............................................808 SYSTEM LEAK TESTING...........................................................809 Electronic Leak Detector..................................................809 Tracer Dyes...............................................................809 Soap and Water............................................................809 RECOVERING AND RECYCLING THE REFRIGERANT......................................810 Performing the Recovery Cycle.............................................810 Performing the Recycling Procedure........................................810 Evacuating and Charging the A/C System....................................810 SYSTEM REPAIR.................................................................811 System Flushing...........................................................811 COMPONENT REPLACEMENT.........................................................811 Hoses and Fittings........................................................811 Lines.....................................................................811 Expansion Valve...........................................................812 Receiver-Drier............................................................812 Thermostat................................................................812 Compressor................................................................812 Accumulator...............................................................812 Clutch....................................................................813 Servicing the Compressor Clutch...........................................813 Pulley Removal............................................................815 Clutch Coil Check.........................................................816 Pulley Installation.......................................................816 Clutch Assembly Installation..............................................816 EVACUATING THE SYSTEM.........................................................818 CHARGING THE A/C SYSTEM.......................................................820 TROUBLESHOOTING...................................................................821 Preliminary Checks............................................................821 Diagnosis Of Gauge Readings And System Performance............................821 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS....................................822 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................828 SECTION N5 - OPERATOR CAB CONTROLS - INDEX............................................830 OPERATOR CAB CONTROLS.............................................................832 STEERING COLUMN...............................................................832 Removal...................................................................832 Installation..............................................................832 STEERING WHEEL AND CONTROLS...................................................834 DYNAMIC RETARDING.............................................................834 RETARDER CONTROL LEVER....................................................835 DYNAMIC RETARDER/SERVICE BRAKE PEDAL......................................835 ACCELERATOR (THROTTLE) PEDAL..............................................835 Starting on a Grade With a Loaded Truck...................................835 GRADE/SPEED RETARD CHART......................................................836 HEATER / AIR CONDITIONER VENTS................................................837 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.............................837 DEFROSTER VENT CONTROL SWITCH.............................................837 HEAT VENT CONTROL SWITCH..................................................837 FAN CONTROL KNOB..........................................................837 AIR CONDITIONER CONTROL KNOB..............................................837 OUTSIDE/INSIDE AIR CONTROL SWITCH.........................................837 SELECTION CONTROL SWITCH..................................................837 HEATER/AIR CONDITIONER VENTS..............................................837 INSTRUMENT PANEL..............................................................838 OVERHEAD PANEL AND DISPLAYS...................................................838 F-N-R SELECTOR SWITCH.....................................................839 HOIST CONTROL LEVER.......................................................840 OVERRIDE /FAULT RESET SWITCH..............................................841 10, FIGURE 5-5 - BLANK....................................................841 RETARD SPEED CONTROL (RSC) "OFF/ON" SWITCH................................841 RETARD SPEED CONTROL (RSC) ADJUST DIAL....................................841 TCI DOWNLOAD PORT.........................................................842 PASSENGER SEAT............................................................842 INSTRUMENT PANEL AND INDICATOR LIGHTS.............................................844 CONTROL SYMBOLS...............................................................844 INSTRUMENT PANEL (Figure 5-6).................................................844 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)...............................846 KEY SWITCH....................................................................846 Starting......................................................................846 Cold Weather Starting.........................................................846 Normal Engine Shutdown........................................................846 Operation.....................................................................847 PARKING BRAKE CONTROL.........................................................848 AC DRIVE SYSTEM TEMPERATURE GAUGE.............................................850 STATUS / WARNING INDICATOR LIGHT SYMBOLS..........................................853 SECTION P.....................................................................860 LUBRICATION AND SERVICE.......................................................860 INDEX.........................................................................860 SECTION P - LUBRICATION AND SERVICE - INDEX...............................................860 SECTION P2 - LUBRICATION AND SERVICE - INDEX..........................................862 LUBRICATION AND SERVICE...........................................................864 930E SERVICE CAPACITIES.......................................................864 HYDRAULIC TANK SERVICE........................................................864 Adding Oil................................................................864 WHEEL MOTOR SERVICE...........................................................864 COOLANT LEVEL CHECK...........................................................865 RADIATOR FILLING PROCEDURE....................................................865 LUBRICATION CHART.............................................................866 10 HOUR (DAILY) INSPECTION....................................................867 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................870 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................871 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................872 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................875 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.................................876 5000 HOUR MAINTENANCE CHECKS..................................................877 SECTION P3 - LINCOLN AUTOMATIC LUBRICATION SYSTEM - INDEX.............................878 LINCOLN AUTOMATIC LUBRICATION SYSTEM..............................................880 System Components.............................................................880 System Operation..............................................................882 GENERAL INSTRUCTIONS..........................................................883 Lubricant Required for System.............................................883 System Priming............................................................883 SYSTEM CHECKOUT...............................................................883 24 VDC SOLID STATE TIMER CHECK................................................884 24 VDC Solid State Timer Adjustment.......................................884 INJECTORS (SL-1 Series "H")...................................................885 Injector Specifications...................................................885 Injector Adjustment.......................................................885 INJECTOR OPERATION............................................................886 PUMP CYCLE TIMER (FLASHER TIMER)..............................................887 Pump Cycle Timer (Flasher Timer) Installation.............................887 Pump Cycle Timer (Flasher Timer) Adjustment:..............................887 Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (N.C.)............887 PRESSURE REDUCER ADJUSTMENT...................................................889 TROUBLESHOOTING CHART.............................................................890 Preventative Maintenance Procedures...............................................893 Daily Lubrication System Inspection...........................................893 250 Hour Inspection...........................................................893 SECTION Q ALPHABETICAL INDEX..............................................................894 SECTION R.................................................................................898 HH337 - HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC..................................900 HH348 - HYDRAULIC BRAKE SYSTEM SCHEMATIC..............................................901 EG9625 - ELECTRICAL WIRING SCHEMATIC..................................................902
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Aryan Kamari –
great resource!