Komatsu 930E-2 Dump Truck Shop Manual CEBM006402 PDF

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Komatsu 930E-2 Dump Truck Shop Manual CEBM006402 – PDF DOWNLOAD

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Komatsu 930E-2 Dump Truck Shop Manual CEBM006402 – PDF DOWNLOAD 

Language : English
Pages : 937
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E-2 Dump Truck Shop Manual CEBM006402 – PDF DOWNLOAD

MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – MAJOR COMPONENT DESCRIPTION 11
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX 15
GENERAL SAFETY 17
Safety Rules 17
Truck Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 17
Fire Extinguishers And First Aid Kits 18
Precautions For High Temperature Fluids 18
Asbestos Dust Hazard Prevention 18
Fire Prevention For Fuel And Oil 18
ROPS Precautions 19
Preventing Injury From Work Equipment 19
Precautions For Optional Attachments 19
Precautions When Starting The Machine 19
PRECAUTIONS FOR TRUCK OPERATION 20
Safety Is Thinking Ahead 20
Safety At The Worksite 20
Fire Prevention 20
Preparing For Operation 20
Ventilation For Enclosed Areas 20
Mirrors, Windows, And Lights 20
In The Operator’s Cab – Before Starting The Engine 21
OPERATING THE MACHINE 21
Starting The Engine 21
Truck Operation – General 21
Traveling In The Truck 22
Precautions When Traveling In Reverse 22
Traveling On Slopes 22
Ensuring Good Visibility 23
Operating On Snow 23
Avoid Damage To The Dump Body 23
Driving Near High Voltage Cables 23
When Loading The Truck 23
When Dumping 23
Working On Loose Ground 23
Parking The Machine 24
TOWING 24
WORKING NEAR BATTERIES 24
Jump Starting With Booster Cables 24
PRECAUTIONS FOR MAINTENANCE 25
BEFORE PERFORMING MAINTENANCE 25
Stopping The Engine Before Service 25
Warning Tag 25
Proper Tools 25
Securing The Dump Body 25
DURING MAINTENANCE 26
Personnel 26
Attachments 26
Working Under The Machine 26
Keeping The Machine Clean 26
Rules To Follow When Adding Fuel Or Oil 26
Radiator Coolant Level 26
Use Of Lighting 26
Precautions With The Battery 27
Handling High Pressure Hoses 27
Precautions With High Pressure Oil 27
Maintenance Near High Temperatures And High Pressures 27
Rotating Fan And Belts 27
Waste Materials 27
TIRES 28
Handling Tires 28
Storing Tires After Removal 28
ADDITIONAL JOB SITE RULES 29
WHEN REPAIRS ARE NECESSARY 30
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK 31
Preliminary Procedures before Welding or Performing Maintenance 31
Normal Engine Shutdown Procedure 31
Engine Shutdown Procedure before Welding or Performing Maintenance 31
TRUCK OPERATION 34
PREPARING FOR OPERATION 34
Safety Is Thinking Ahead 34
WALK AROUND INSPECTION 34
ENGINE START-UP SAFETY PRACTICES 38
AFTER STARTING THE ENGINE 39
Additional Guidelines 39
MACHINE OPERATION SAFETY PRECAUTIONS 39
MACHINE OPERATION ON THE HAUL ROAD 40
DYNAMIC RETARDING OPERATION 41
Dynamic Retarder Control Lever 41
Dynamic Retarder/Service Brake Pedal 41
STARTING ON A GRADE WITH A LOADED TRUCK 42
PASSING 42
LOADING 42
DUMPING 42
Raising The Dump Body 42
Lowering The Dump Body 43
TOWING 44
SAFE PARKING PROCEDURES 45
NORMAL ENGINE SHUTDOWN PROCEDURE 45
DELAYED ENGINE SHUTDOWN PROCEDURE 45
SUDDEN LOSS OF ENGINE POWER 46
SECTION A4 – WARNINGS AND CAUTIONS 47
SECTION A5 – STANDARD CHARTS AND TABLES 55
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX 61
STORAGE AND IDLE MACHINE PREPARATION 63
Short Term Idle Periods 63
PREPARATION FOR STORAGE 64
REMOVAL FROM STORAGE 65
RECONDITIONING AN IDLE VEHICLE 67
ENGINE OPERATION 70
After The Engine Has Started 71
ENGINE STORAGE 72
Preparing Engine For Storage 72
Temporary Storage (30 Days Or Less) 72
Extended Storage (more Than 30 Days) 72
RESTORING AN ENGINE AFTER EXTENDED STORAGE 74
ELECTRIC DRIVE TRUCKS 75
Storage Instructions and Procedures 75
Placing Equipment Into Storage 75
Storing A Truck That Is Operational 75
Storing A Truck That Is Not Operational 76
Storing A Major Component 76
Periodic Inspections 77
Placing Equipment Into Service After Storage 77
When A Truck Is Operational 77
When A Truck Is Not Operational 77
For The First Hour 78
SECTION B – STRUCTURES – INDEX 79
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 81
STRUCTURAL COMPONENTS 83
Preparation 83
GRILLE, HOOD AND LADDER 84
Removal 84
Installation 84
DECKS 85
RIGHT DECK AND COMPONENTS 85
Removal 85
Installation 86
LEFT DECK 86
Removal 86
Installation 86
CENTER DECK 86
SECTION B3 – DUMP BODY – INDEX 87
DUMP BODY 89
Removal 89
Installation 90
BODY PADS 91
Adjustment 91
BODY GUIDE 92
HOIST LIMIT SWITCH 92
BODY UP SWITCH 92
BODY-UP RETENTION CABLE 92
ROCK EJECTORS 93
Rock Ejectors (Type I) 93
Inspection 93
Rock Ejectors (Type II) 94
Inspection 94
SECTION B4 – FUEL TANK – INDEX 95
FUEL TANK 97
Removal 98
Installation 98
Repair 98
Cleaning 98
FUEL GAUGE SENDER 99
Removal 99
Installation 99
LOW FUEL SWITCH 99
WIGGINS QUICK FILL FUEL SYSTEM 100
FUEL RECEIVER 100
TANK BREATHER VALVE 100
Removal 100
Installation 100
Disassembly 100
Assembly 100
LEFT SIDE FILL 101
FUEL – WATER SEPARATOR 102
Installation 102
Filter Service 103
Backflushing Procedure 103
Filter Element Replacement 103
SECTION C – ENGINE – INDEX 105
SECTION C2 – POWER MODULE – INDEX 107
Preparation 109
Preparation for Removal 110
Power Module Removal 113
Power Module Installation 115
Power Module Hookup 115
Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul) 117
SECTION C3 – COOLING SYSTEM – INDEX 119
COOLING SYSTEM 121
COOLING SYSTEM DESCRIPTION 121
Coolant Flow 121
RADIATOR 122
Removal 122
RADIATOR REPAIR 124
Internal Inspection 124
External Cleaning 124
Disassembly 125
Cleaning and Inspection 126
Assembly 126
Pressure Testing 127
Additional Service Information 127
Installation 128
RADIATOR FILL PROCEDURE 128
Radiator Pressure Regulator Valve 129
COOLING SYSTEM TROUBLESHOOTING 129
SECTION C4 – POWERTRAIN – INDEX 131
POWER TRAIN 133
ALTERNATOR REMOVAL PROCEDURE 133
Removal (MTU/DDC 4000 Engine) 133
ENGINE/ALTERNATOR MATING 135
General Instructions 135
MEASURING PROCEDURE 135
Joining Alternator and MTU/DDC Engine 137
ENGINE 138
Removal 138
Service 138
Installation 138
SECTION C5 – AIR CLEANERS – INDEX 139
AIR CLEANERS 141
AIR CLEANERS 141
Operation 141
General Service Information 141
FILTER ELEMENT REPLACEMENT 142
Main Filter Element Cleaning 143
Precleaner Section 144
Cleaning Precleaner Tubes 144
AIR INTAKE TROUBLESHOOTING 145
SECTION C7 – FAN CLUTCH – INDEX 147
FAN CLUTCH 149
REMOVAL & INSTALLATION TOOLING 149
FAN CLUTCH – DISASSEMBLY 152
CLEANING AND INSPECTION 162
ASSEMBLY – FAN CLUTCH 166
TEST PROCEDURE 180
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX 181
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX 183
24VDC ELECTRIC SUPPLY SYSTEM 185
ELECTRICAL SYSTEM DESCRIPTION 185
BATTERIES 185
Maintenance and Service 185
Troubleshooting 185
BATTERY SUPPLY SYSTEM 187
24VDC Battery Charging Alternator 187
Battery Box 187
Battery Control Box 187
System Battery Starter Disconnect Relay 187
Battery Disconnect Switches 188
24VDC Auxiliary Battery Connectors 188
Battery Equalizer 189
Troubleshooting 189
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX 191
24 VDC ELECTRICAL SYSTEM COMPONENTS 193
PASSENGER SEAT BASE COMPARTMENT 193
TRUCK SHUTDOWN PROCEDURE 193
COMPONENTS 193
Tail Light Resistor Diode Assemblies 193
5 Minute Idle Timer Components 193
Inclinometer 195
Brake Warning Buzzer (BWB) 195
Alarm Indicating Device (AID) System 195
ELECTRICAL INTERFACE CABINET 198
Lubrication System Timer 198
Barometric Pressure Transducer 198
Special Interface Module 198
Power Distribution Terminals 198
Truck Control Interface Panel 198
Control Power Relay 198
Circuit Breaker Panel 198
Diode Board – DB1 200
Diode Testing 200
RELAY BOARDS 201
Relay Boards – RB1, RB2, RB3, RB4, RB5 201
Service 201
Relay Board Identification 202
Relay Board Functions 203
Relay Board 6 (RB6) 204
BODY-UP SWITCH 205
Operation 205
Adjustment 205
Service 205
HOIST LIMIT SWITCH 206
Operation 206
Adjustment 206
Service 206
SECTION D5 – DDEC ELECTRONIC ENGINE CONTROL – INDEX 209
DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE 211
COMPONENT DESCRIPTION 212
Electronic Control Module 212
Electronic Unit Nozzles 214
System Sensors and Operator Inputs 214
ENGINE PROTECTION SYSTEM 215
DIAGNOSTICS 216
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX 217
BATTERY CHARGING ALTERNATOR 219
ELECTRICAL SYSTEM DESCRIPTION 219
BATTERY 219
Maintenance and Service 219
Troubleshooting 219
BATTERY CHARGING SYSTEM (Niehoff) 221
General Description 221
TROUBLESHOOTING PROCEDURES (On-Truck) 221
Equipment Required: 221
Preliminary Checks 222
Test Setup 222
Test Procedure 222
Regulator Bypass Test 223
ON VEHICLE TROUBLESHOOTING GUIDE 225
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage 225
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 225
CHARGE VOLT AND AMP VALUES 226
DEFINITIONS 226
ADVANCED SYSTEM TROUBLESHOOTING 227
Static Test – Engine OFF, Key ON, Battery Switch ON 227
Go To Alternator 227
Go To Regulator (If Required) 228
Go To Regulator Connector On The Alternator 228
ALTERNATOR OVERHAUL 229
ALTERNATOR DIMENSIONS 229
ALTERNATOR SPECIFICATIONS 230
SERVICE PARTS 231
ON-VEHICLE TEST 233
Equipment: 233
Preliminary Checks: 233
Test Set-up 233
Test Procedure 233
ON-VEHICLE TEST 234
Bypass Test: 234
BENCH TEST 235
STATIC TESTS 236
Regulator Tests 236
Control Box Tests 237
ALTERNATOR DISASSEMBLY 239
ASSEMBLY- ALTERNATOR 244
BF4822 STATOR SERVICE TOOL INSTRUCTIONS 253
Stator Removal And Replacement 253
Stator Installation 254
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 257
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 259
ELECTRICAL PROPULSION SYSTEM COMPONENTS 261
GENERAL SYSTEM DESCRIPTION 261
SYSTEM COMPONENTS 263
Auxiliary Blower System 263
Propulsion System Controller (PSC) 263
TRUCK CONTROL INTERFACE PANEL (TCI) 264
Diagnostic Information Display 265
DID PANEL EVENT CODES 265
PSC SOFTWARE FUNCTIONS 290
Input Processing 290
STATE MANAGEMENT 290
State Machine 290
Transitions Between States 291
DC Link State 293
Powering the Link 293
De-Powering the Link 293
Control Functions 293
Engine Control 293
ALTERNATOR FIELD CONTROL 294
Desired Three-Phase Voltage 294
Desired DC Link Voltage 294
Self-load 294
Propel Torque Control 295
Retard Torque Control 295
Wheel Slide Control 295
Resistor Grid Control 296
Chopper Voltage Control 296
AUXILIARY BLOWER CONTROL 296
EVENT PROCESSING 296
Event Detection 296
Power On Tests 296
Initiated Tests 297
Periodic Tests 297
EVENT RESTRICTIONS 297
EVENT LOGGING AND STORAGE 297
Event History Buffer 298
Data Packs 298
To Record and Save a Data Pack to a Floppy Disk 298
Event Reset 299
SERIAL DATA COMMUNICATIONS 300
PSC – TCI Communications processing 300
PSC – PTU Communications Processing 300
Inverter Communications Processing 300
OUTPUT PROCESSING 301
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 301
Fast Start 301
Engine Shutdown/Engine Not Running 301
Limp Home Mode 301
Entering/Exiting Limp Home Mode 301
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 302
ELECTRONIC ACCELERATOR AND RETARD PEDALS 312
Removal 312
Installation 312
Disassembly 312
Assembly 312
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 313
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 315
AC DRIVE SYSTEM MAINTENANCE 315
TRUCK SHUTDOWN PROCEDURES 315
NORMAL TRUCK SHUTDOWN PROCEDURE 316
SHUTDOWN AFTER SYSTEM FAILURE 317
SYSTEM CHECKOUT 318
Battery and Control Checks of System WITH Battery Power OFF 318
Battery and Control Circuit Checks of System With Battery Power ON 321
Checks with Key Switch OFF 322
CPU Battery Checks 324
MEMORY BACKUP BATTERY REPLACEMENT 324
TCI PROGRAMMING 325
PSC PROGRAMMING 325
INVERTER PROGRAMMING 326
TCI CHECKOUT 326
Modular Mining Communication Port 327
TCI Input Checks 328
TCI Digital Output Tests 330
TCI Digital Input Tests 332
PSC Checkout Procedure 334
PSC Digital Input Checks 338
Miscellaneous Checks 339
A3PV Panel 339
LINKV Panel 339
Thermistor Checks 339
17FM384 Panel Check 339
Pedal Percentages and Meter Calibration 340
Meter Calibration Procedure 340
Reprogram With Serial Numbers and Pedal Percentages 342
LOAD TESTING 344
Preload Checks 344
ADDITIONAL TRUCK CHECKS 346
On-Board Load Testing 348
Preparation 348
Initiate Loadbox Test 351
Manual Offset HP Output Adjustment 353
TROUBLESHOOTING 355
PVM Optimum Load Curve Handshaking Troubleshooting 355
MISCELLANEOUS COMPONENT REPAIR 356
Troubleshooting Phase Modules and Chopper Modules 356
Phase Module Removal and Snubber Resistor Replacement 356
Snubber Resistor Installation 357
Phase Module Installation 357
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 358
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 361
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 362
IGBT TROUBLESHOOTING 363
SECTION G – REAR AXLE, SPINDLE AND WHEELS – INDEX 365
SECTION G2 – TIRES AND RIMS – INDEX 367
TIRES AND RIMS 369
WHEEL STUD MAINTENANCE 370
FRONT TIRES AND RIMS 371
Removal 371
Installation 372
REAR TIRES AND RIMS 373
Removal 373
Installation 374
RIM 375
Tire Removal 375
Tire Installation 376
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 379
FRONT WHEEL HUB AND SPINDLE 381
WHEEL HUB AND SPINDLE ASSEMBLY 381
Preparation 381
Removal 381
Installation – Wheel Hub and Spindle Assembly 384
Disassembly – Wheel Hub and Spindle Assembly 385
Cleaning and Inspection – Wheel Hub and Spindle Assembly 385
Assembly – Wheel Hub and Spindle Assembly 387
Wheel Bearing Adjustment: 387
Brake Installation 388
Seal Assembly Gap Check 389
STEERING CYLINDERS AND TIE ROD 390
Spherical Bearing Wear Limits 390
Removal – Steering Cylinder and Tie Rod 391
Installation – Steering Cylinder and Tie Rod 392
Bearing Replacement 392
TOE-IN ADJUSTMENT 393
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 395
REAR AXLE HOUSING ATTACHMENT 397
PIVOT PIN 397
Removal 397
Installation 397
PIVOT EYE BEARING 398
Disassembly 398
Assembly 398
PIVOT EYE REPAIR 399
Removal 399
Disassembly 399
Assembly 399
Installation 399
ANTI-SWAY BAR 400
Removal 400
Installation 400
Disassembly 400
Cleaning and Inspection 400
Assembly 400
SECTION G5 – REAR AXLE HOUSING – INDEX 401
REAR AXLE HOUSING 403
REAR AXLE HOUSING 403
Preparation 403
Removal 403
Cleaning and Inspection – Rear Axle Housing 405
Installation – Rear Axle Housing 405
WHEEL MOTOR 406
Preparation 406
Removal 406
Cleaning and Inspection – Wheel Motor 407
Installation – Wheel Motor 408
WHEEL MOTOR GEAR OIL 411
Filtering Requirements 411
Particle Size Analysis 411
Flushing 411
Oil Sample Analysis 412
ELEMENT SPECIFICATION CHARTS 413
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 417
SECTION H2 – FRONT SUSPENSIONS – INDEX 419
FRONT SUSPENSION 421
Removal 421
Installation – Front Suspension 422
“Turn-Of-The-Nut” Tightening Procedure 425
MINOR REPAIRS (LOWER BEARING & SEALS) 426
Removal – Bearing Retainer 426
Installation – Bearing Retainer 426
MAJOR SUSPENSION REBUILD 428
Disassembly 428
Assembly 428
SECTION H3 – REAR SUSPENSIONS – INDEX 431
REAR SUSPENSIONS 433
Removal 433
Installation – Rear Suspension 435
Disassembly – Rear Suspension 436
Cleaning and Inspection – Rear Suspension 436
Assembly – Rear Suspension 436
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 439
SUSPENSION OILING AND CHARGING PROCEDURE 441
GENERAL 441
EQUIPMENT LIST 441
Hydrair® Charging Kit 441
Installation of Charging Kit 441
Removal of Charging Kit 442
Support Blocks For Oiling And Charging Dimensions 442
FRONT SUSPENSION 443
Front Suspension Oiling 443
Front Suspension Nitrogen Charging 444
REAR SUSPENSION 445
Rear Suspension Oiling 445
Rear Suspension Nitrogen Charging 446
OIL AND NITROGEN SPECIFICATIONS CHART 448
SECTION J – BRAKE CIRCUIT – INDEX 449
SECTION J2 – BRAKE CIRCUIT – INDEX 451
BRAKE CIRCUIT 453
SERVICE BRAKE CIRCUIT 453
SECONDARY BRAKING AND AUTOMATIC APPLY 455
PARKING BRAKE CIRCUIT 455
BRAKE LOCK CIRCUIT 456
WARNING CIRCUIT 456
Rear Axle Brake Lines 458
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 459
BRAKE CIRCUIT COMPONENT SERVICE 461
BRAKE VALVE 461
Rebuild Criteria 461
Removal 462
Installation 462
DISASSEMBLY 463
Cleaning and Inspection 466
ASSEMBLY 466
Actuator Base Threaded Inserts 466
Boot and Cap 466
Valve Body Seal Installation 466
Regulator Sleeve O-ring Installation 467
Actuator Plunger O-ring Installation 467
Assembly of Valve 467
DIFFERENTIAL PRESSURE SWITCH 469
Disassembly 469
Cleaning and Inspection 469
Assembly 469
VALVE BENCH TEST AND ADJUSTMENT 470
Test Set Up Procedure 471
Brake Valve Output Pressure Adjustment 471
Differential Pressure Switch Adjustment 471
Final Test and Adjustment 472
Installation Of Brake Pedal Actuator Assembly to Brake Valve 473
Installation of Retard Pedal To Brake Pedal 473
DUAL RELAY VALVE 475
Removal 475
Installation 475
Disassembly 477
Cleaning and Inspection 477
Assembly 477
DIFFERENTIAL PRESSURE SWITCH 478
Disassembly 478
Cleaning and Inspection 478
Assembly 478
VALVE TEST AND ADJUSTMENT 479
Test Set Up Procedure 480
Brake Valve Output Pressure Adjustment 480
Differential Pressure Switch Adjustment 481
BRAKE MANIFOLD 482
Removal 482
Installation 483
Disassembly 483
Cleaning and Inspection 483
Assembly 483
HYDRAULIC BRAKE ACCUMULATORS 484
Brake Accumulator Bleed Down Procedure 484
ACCUMULATORS – HYDRAULIC COMPONENT CABINET 484
Removal 484
Installation 484
Disassembly 484
Cleaning and Inspection 486
Assembly 486
BLADDER ACCUMULATOR CHARGING PROCEDURE 488
Temperature During Precharge 489
Precharge Maintenance 489
Accumulator Storage Procedures 490
Bladder Storage Procedures 491
ACCUMULATORS – FRAME MOUNTED 491
Removal 491
Installation 491
Disassembly 493
Cleaning and Inspection 493
Assembly – Accumulator 494
Accumulator Testing 494
ACCUMULATOR CHARGING PROCEDURE 495
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 496
Removal 496
Installation 496
Disassembly and Adjustment 496
Potentiometer Check 498
Assembly 498
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 499
BRAKE CIRCUIT CHECK-OUT PROCEDURE 501
EQUIPMENT REQUIRED 503
INITIAL SYSTEM SET-UP 504
BRAKE SYSTEM CHECKOUT 505
Failure Modes Check-Out 506
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 509
CHECK-OUT PROCEDURE 513
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 515
WET DISC BRAKE ASSEMBLY 517
OPERATION 517
MAINTENANCE 518
Brake Disc Wear Indicator 518
Removal/Installation – Wet Disc Brake Assembly 518
BRAKE REBUILD 520
Disassembly 520
Cleaning and Inspection 523
Assembly 524
Floating Ring Seal Assembly/Installation 527
WET DISC BRAKE BLEEDING PROCEDURE 530
SECTION J7 – PARKING BRAKE – INDEX 531
PARKING BRAKE 533
OPERATION 533
MAINTENANCE 534
Inspection – Parking Brake 534
Removal – Parking Brake 534
Installation – Parking Brake 535
Disassembly – Parking Brake 536
Cleaning and Inspection – Parking Brake 536
Assembly – Parking Brake 536
PARKING BRAKE BLEEDING PROCEDURE 538
SECTION L – HYDRAULIC SYSTEM – INDEX 539
SECTION L2 – HYDRAULIC SYSTEM – INDEX 541
HYDRAULIC SYSTEM 543
Hoist Circuit Operation 544
Steering Circuit Operation 546
Disc Brake Cooling System 548
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 551
HYDRAULIC SYSTEM COMPONENT REPAIR 553
HOIST PUMP 553
Removal 553
Installation 555
Disassembly 556
Inspection of Parts 560
Assembly 560
TROUBLESHOOTING GUIDE (HOIST PUMP) 565
HYDRAULIC TANK 566
Filling Instructions 566
Removal – Hydraulic Tank 566
Installation – Hydraulic Tank 567
HYDRAULIC TANK STRAINERS 567
Removal 567
Inspect and Clean 567
Installation 567
HYDRAULIC TANK BREATHERS 568
SECTION L4 – STEERING CIRCUIT – INDEX 569
STEERING CIRCUIT 571
STEERING CIRCUIT OPERATION 571
COMPONENT DESCRIPTION 572
Steering Control Unit 572
Bleeddown Manifold Valve 573
Bleeddown Solenoid 573
Relief Valves 575
Hoist Limit Solenoid 575
Accumulators 575
Low Precharge Warning Switch 575
High Pressure Filters 575
Quick Disconnect Ports 575
Flow Amplifier 576
FLOW AMPLIFIER SYSTEM OPERATION 578
No Steer 578
Steering Left 580
Steering Right 582
No Steer, External Shock Load 584
STEERING PUMP 586
Operation 586
High Altitude Operation 586
PRINCIPLE OF OPERATION 588
Full Pump Volume 588
Half Pump Volume 588
Neutral Position 588
ADDITIONAL STEERING PUMP INFORMATION 589
SECTION L5 – STEERING CONTROL UNIT – INDEX 591
STEERING CONTROL UNIT 593
Removal 593
Installation 593
STEERING CONTROL UNIT REBUILD 594
Disassembly 594
Cleaning and Inspection – Steering Control Unit 595
Assembly – Steering Control Unit 597
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 601
STEERING CIRCUIT COMPONENT REPAIR 603
BLEEDDOWN MANIFOLD VALVE 603
Removal 603
Installation 603
ACCUMULATORS 604
Removal 604
Installation 604
Disassembly – Accumulators 605
Cleaning and Inspection – Accumulators 605
Assembly – Accumulators 606
Testing – Accumulators 606
STEERING ACCUMULATOR CHARGING PROCEDURE 607
FLOW AMPLIFIER 608
Removal 608
Installation 608
FLOW AMPLIFIER REBUILD 608
Disassembly – Flow Amplifier 610
Assembly – Flow Amplifier 611
STEERING CYLINDERS 612
Disassembly – Steering Cylinder 613
Piston Seal & Bearing Installation 613
Assembly – Steering Cylinder 613
Test – Steering Cylinder 613
STEERING AND BRAKE PUMP 614
Removal 614
Installation 614
Disassembly – Steering and Brake Pump 616
Control Piston Group 616
Valve Plate Group 616
Rotating Group 619
Swashblock Group 619
Driveshaft Group 619
Inspection – Steering and Brake Pump 619
Control Piston Group 619
Valve Plate Group 619
Rotating Group 619
Swashblock Group 621
Driveshaft Group 622
Compensator Block and Unloader Module 622
Stroke Adjuster Assembly 622
Assembly – Steering and Brake Pump 622
Swashblock Group 622
Driveshaft Group 623
Rotating Group 623
Control Piston Group 623
Valve Plate Group 624
TROUBLESHOOTING CHART 625
SECTION L7 – HOIST CIRCUIT – INDEX 631
HOIST CIRCUIT 633
HOIST CIRCUIT OPERATION 633
COMPONENT DESCRIPTION 634
Hydraulic Tank 634
Hydraulic Pump 634
High Pressure Filters 634
Hoist Valve 634
Inlet Sections – Hoist Valve 634
Spool Sections – Hoist Valve 635
Hoist Pilot Valve 635
Bleeddown Manifold 636
Hoist-up Limit Solenoid 636
Pilot Operated Check Valve 636
Overcenter Manifold 636
HOIST CIRCUIT OPERATION 637
Float Position Of Pilot Valve With Truck Body On Frame 638
Power Up Operation 640
Hold Operation 642
Power Down Operation 644
Float Operation 646
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 649
HOIST CIRCUIT COMPONENT REPAIR 651
HOIST VALVE 651
Removal – Hoist Valve 651
Installation – Hoist Valve 652
O-Ring Replacement 652
INLET SECTION 653
Disassembly – Inlet Section 653
Cleaning and Inspection – Inlet Section 654
Assembly – Inlet Section 654
REAR SPOOL SECTION (Work Ports) 654
Disassembly – Rear Spool Section 654
Cleaning and Inspection – Rear Spool Section 656
Assembly – Rear Spool Section 656
FRONT SPOOL SECTION (Tank Ports) 657
Disassembly 657
Cleaning and Inspection 657
Assembly 657
HOIST PILOT VALVE 659
Removal – Hoist Pilot Valve 659
Installation – Hoist Pilot Valve 659
Disassembly – Hoist Pilot Valve 660
Cleaning and Inspection – Hoist Pilot Valve 661
Assembly – Hoist Pilot Valve 661
HOIST CYLINDERS 662
Removal – Hoist Cylinder 662
Installation – Hoist Cylinder 663
Disassembly – Hoist Cylinder 665
Cleaning and Inspection – Hoist Cylinder 666
Assembly – Quill And Cylinder 667
Installation – Quill 667
Installation – Check Balls And Plugs In Quill 668
Assembly – Hoist Cylinder 669
DISABLED TRUCK DUMPING PROCEDURE 670
Hookup 670
DUMPING PROCEDURE 670
Raising the Body 670
Lowering the Body 670
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 671
HYDRAULIC SYSTEM FILTERS 673
HOIST CIRCUIT FILTER 673
Filter Element Replacement 673
Removal – Hoist Circuit Filter 674
Installation – Hoist Circuit Filter 674
Indicator Switch – Hoist Circuit Filter 674
STEERING CIRCUIT FILTER 675
Filter Element Replacement 675
Removal – Steering Circuit Filter 676
Installation – Steering Circuit Filter 676
Indicator Switch – Steering Circuit Filter 676
INDICATOR SWITCH 676
Test Procedure 676
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 679
HYDRAULIC CHECK-OUT PROCEDURE 681
GENERAL INFORMATION 681
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 681
Equipment Requirements 682
Pump Pressure Control Adjustments 682
Steering Control Unit and Flow Amplifier Leakage Test 683
Bleeddown Manifold Leakage Test 683
Steering/Brake Pump Stroke Adjustment 684
Shock And Suction Valves 685
Equipment Requirements 685
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 686
Equipment Requirements 686
Pressure Checks 686
Brake Cooling Circuit Test 686
Power Up Relief Pressure Test 687
Adjustment 687
Power Down Relief Pressure Test 688
Adjustment 688
Hoist Counterbalance Valve Adjustment Preparation 689
Counterbalance Valve Pressure Check 689
Counterbalance Valve Adjustment 690
HYDRAULIC SYSTEM FLUSHING PROCEDURE 691
Preparation 691
Flushing Procedure 691
Filter Element Replacement 692
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 693
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 694
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 695
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX 697
FIRE CONTROL SYSTEM (MANUAL) 699
Operation 699
Inspection and Maintenance 699
Recharging Procedures 700
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 701
Control Module 701
Actuator 702
Linear Detection Wire 702
Power Wire 702
Test Kit 702
Squib 702
Securing the Detection Wire 703
Preliminary Test Before Final Hook-Up 703
Installation Procedure for Squib 705
Placing the Electric Detection & Actuation System Into Service 705
INSPECTION AND MAINTENANCE SCHEDULES 706
Daily 706
Normal Maintenance Based On Actual Operating Hours 706
IN CASE OF FIRE 707
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 709
SECTION M8 – SPECIAL TOOLS 711
SECTION M20 – PAYLOAD METER II – ON BOARD WEIGHING SYSTEM – INDEX 717
GENERAL INFORMATION 719
Haul Cycles 719
LIGHTS, SWITCHES AND COMPONENTS 720
TIPS FOR OPERATION 721
EXTERNAL DISPLAY LIGHTS 721
THEORY OF OPERATION 722
Basic Description 722
Inclinometer 722
Linkage Factor 722
Gain Factor 723
Brake Lock 723
Sources of Error 723
Typical Data From Service Check Mode 723
Example Calculation of Payload 724
Viewing Payload Calculation Inputs 724
Checking the Gain 725
Adjusting the Gain 725
TYPES OF DATA STORED 726
Cycle Data 726
Engine ON/OFF Data 727
Fault Codes and Warning Data 727
Engine Operation 728
Total Payload and Total Number of Cycles 728
Other Data 728
OPERATOR FUNCTIONS 729
Using the Operator Load Counter 729
Viewing the Operator Load Counter 729
Clearing the Operator Load Counter 729
Dimming the Lights on the Display 729
INITIAL SETUP OF PAYLOAD METER 730
Switch Settings 730
Checking the Operator Check Mode 731
Checking the Service Check Mode 731
Checking the Gt setting: 732
Checking the Inclinometer Settings 732
Calibrating a Truck 732
DISPLAYS AT START-UP 733
Normal Operation 733
SETUP AND MAINTENANCE 734
Setting The Speed Limit 734
Setting the Option Code 734
Setting The Machine I D Code 735
Setting The Operator I D Code 735
Setting The Time and Date 735
DOWNLOAD OF INFORMATION 736
DISPLAY OF FAULT CODES 736
Monitoring Input Signals 740
Service Check Mode 740
UP FACTOR – PAYLOAD CALCULATION GAIN 741
PL MODE -LOAD CALCULATION TIMING 741
FINAL GEAR RATIO SELECTION 742
BATTERY REPLACEMENT PROCEDURE 743
Replacing the Battery 743
After Replacing the Battery 744
SUSPENSION PRESSURE SENSOR 744
Removal 744
Installation 745
INCLINOMETER 745
Removal 745
Installation 745
Adjustment 745
PAYLOAD METER BACK PANEL 746
CONNECTIONS 747
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE 748
PAYLOAD CIRCUIT NUMBERS 749
TROUBLESHOOTING 750
COMMON PROBLEMS 750
Suspension Charging 750
Symptom Table 751
Missing Body-Up Signal 751
Missing Speed Signal 752
F-18: Alternator R-Terminal, Oil Pressure Signals 752
Shorted 18v Sensor Power Supply (930E) 752
FAULT TREE DIAGNOSIS 753
Payload Lights Won’t Illuminate 753
Red, Amber or Green Payload Light Does Not Illuminate 754
Cannot Download – PC Communications 755
PC Communications Configuration 756
F CAL: Payload Meter Won’t Calibrate 757
F-20: Sensor Power Fault 758
F-21, F-25: Left Front Pressure Sensor 760
F-22, F-26: Right Front Pressure Sensor 760
F-23, F-27: Left Rear Pressure Sensor 760
F-24, F-28: Right Rear Pressure Sensor 760
F-31, F-32: Inclinometer 762
Body Up Input 764
Brake Lock Input 765
Speed Signal 766
Adjusting the Speed Sensor 766
CONNECTORS AND PRESSURE SENSORS 768
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM 771
Menu Functions 774
Using Scope 774
Log File Information 774
Connections to Payload Meter II™ 775
USING SCOPE 776
Monitoring Inputs Using Scope 776
Monitoring Suspension Charging Using Scope 776
Pressure Sensor Dummy Loads 779
GAIN ADJUSTMENT WORKSHEET 780
SECTION N – CAB COMPONENTS – INDEX 781
SECTION N2 – TRUCK CAB – INDEX 783
TRUCK CAB 785
Description 785
Preparation 786
Removal – Cab 786
Installation – Cab 788
CAB DOOR 788
Removal 788
Installation 788
Door Adjustment 789
Door Jamb Bolt Adjustment 789
Door Handle Plunger Adjustment 790
Door Glass Replacement 791
Door Window Regulator Replacement 795
Door Handle or Latch Assembly Replacement 795
Door and Door Hinge Seal Replacement 796
Door Opening Seal Removal 796
Installation 796
GLASS REPLACEMENT 797
Adhesive Bonded Windows 797
Replacement Procedure 797
Windshield And Rear Glass 798
Removal 798
Installation 799
SECTION N3 – CAB COMPONENTS – INDEX 801
CAB COMPONENTS 803
WINDSHIELD WIPERS 803
Wiper Motor Replacement 803
Removal 803
Installation 803
Wiper Arm Replacement 803
Removal 803
Installation 804
Wiper Linkage Replacement 804
Removal 804
Installation 804
WINDSHIELD WASHER 805
Operation 805
Service 805
OPERATOR SEAT 806
Adjustment 806
Removal 806
Installation 806
SECTION N4 – OPERATOR COMFORT – INDEX 807
OPERATOR COMFORT 809
HEATER/AIR CONDITIONER 809
Operation 809
HEATER COMPONENTS 810
Circuit Breakers 810
Heater Control Components 810
Heater Coil 810
Fan Motor And Speed Control 811
Actuators 811
Filter Service 811
AIR CONDITIONING SYSTEM 813
Environmental Impact 813
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 814
PRINCIPLES OF REFRIGERATION 814
Air Conditioning 814
Refrigeration – The Act Of Cooling 815
The Refrigeration Cycle 815
AIR CONDITIONER SYSTEM COMPONENTS 816
Compressor (Refrigerant Pump) 816
Service Valves 816
Condenser 816
Receiver-Drier 816
Expansion Block Valve 817
Accumulator 817
Evaporator 817
ELECTRICAL CIRCUIT 818
Thermostat 818
Compressor Clutch 818
Trinary™ Switch 819
SYSTEM SERVICING 820
SERVICE TOOLS AND EQUIPMENT 821
Recovery/Recycle Station 821
Leak Detector 821
Service Valves 822
Vacuum Pump 822
Manifold Gauge Set 823
Installing Manifold Gauge Set 824
Purging Air From Service Hoses 824
SYSTEM PERFORMANCE TEST 825
SYSTEM OIL 826
Handling and Reusing PAG Oil 826
Oil Quantity 826
Checking System Oil 826
REFRIGERANT 827
Recycled Refrigerant 827
Reclaimed Refrigerant 827
Refrigerant Quantity 827
R-134a Refrigerant Containers 827
SYSTEM LEAK TESTING 828
Electronic Leak Detector 828
Tracer Dyes 828
Soap and Water 828
RECOVERING AND RECYCLING THE REFRIGERANT 829
Performing the Recovery Cycle 829
Performing the Recycling Procedure 829
Evacuating and Charging the A/C System 829
SYSTEM REPAIR 830
System Flushing 830
COMPONENT REPLACEMENT 830
Hoses and Fittings 830
Lines 830
Expansion Valve 831
Receiver-Drier 831
Thermostat 831
Compressor 831
Accumulator 831
Clutch 832
Servicing the Compressor Clutch 832
Pulley Removal 834
Clutch Coil Check 835
Pulley Installation 835
Clutch Assembly Installation 835
EVACUATING THE SYSTEM 837
CHARGING THE A/C SYSTEM 839
TROUBLESHOOTING 840
Preliminary Checks 840
Diagnosis Of Gauge Readings And System Performance 840
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 841
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 847
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 849
OPERATOR CAB CONTROLS 851
STEERING COLUMN 851
Removal 851
Installation 851
STEERING WHEEL AND CONTROLS 853
Horn Button 853
Telescope Lock Ring 853
Tilt Wheel Lever 853
Turn Signal Headlight Dimmer 853
DYNAMIC RETARDING 853
Retarder Control Lever 854
Dynamic Retarder/Service Brake Pedal 854
Accelerator (Throttle) Pedal 854
Starting on a Grade With a Loaded Truck 854
GRADE/SPEED RETARD CHART 855
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 856
Defroster Control Switch 856
Outside/Inside Air Control Switch 856
Heat Vent Control Switch 856
Temperature Control Knob 856
Fan Control Knob 856
Heater/Air Conditioner Selector Switch 856
Heater/Air Conditioner Vents 856
INSTRUMENT PANEL 857
OVERHEAD PANEL AND DISPLAYS 857
CENTER CONSOLE 858
F-N-R Selector Switch 858
HOIST CONTROL LEVER 859
To Raise dump body: 859
To lower body: 859
Ash Tray 859
Lighter 859
L H Window Control Switch 859
R H Window Control Switch 859
Engine Shutdown Switch 859
Override/Fault Reset Switch 860
Retard Speed Control (RSC) “Off/On” Switch 860
Retard Speed Control (RSC) Adjust Dial 860
PSC Download Port 861
Engine Diagnostics Download Port 861
TCI Download Port 861
Passenger Seat 861
INSTRUMENT PANEL AND INDICATOR LIGHTS 863
Control Symbols 863
INSTRUMENT PANEL (Figure 5-6) 863
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6) 865
Key Switch 865
Starting 865
Cold Weather Starting 865
Normal Engine Shutdown 865
Engine Shutdown Switch with 5 Minute Idle Timer Delay 866
Operation 866
Fog Lights (Optional) 866
Ladder Light Switch 866
Manual Backup Switch 866
Panel Illumination Lights 867
Cab Air Conditioner/Heater Vents 867
Rotating Beacon Light Switch (Optional) 867
Heated Mirror Switch (Optional) 867
Wheel Brake Lock Control 867
Parking Brake Control 867
Tachometer 868
Right Turn Signal Indicator 868
High Beam Indicator 868
Left Turn Signal Indicator 868
Speedometer 868
Voltmeter 868
Engine Oil Pressure Gauge 868
Water Temperature Gauge 868
Fuel Gauge 868
AC Drive System Temperature Gauge 869
Hydraulic Oil Temperature Gauge 869
Hourmeter 869
Rest Switch 869
Light Switch 870
Windshield Wiper and Washer 870
Panel Light Dimmer 870
STATUS / WARNING INDICATOR LIGHT SYMBOLS 872
SECTION P – LUBRICATION AND SERVICE – INDEX 879
SECTION P2 – LUBRICATION AND SERVICE – INDEX 881
LUBRICATION AND SERVICE 883
930E SERVICE CAPACITIES 883
HYDRAULIC TANK SERVICE 883
Adding Oil 883
WHEEL MOTOR SERVICE 883
COOLANT LEVEL CHECK 884
RADIATOR FILLING PROCEDURE 884
LUBRICATION CHART 885
10 HOUR (DAILY) INSPECTION 886
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 889
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 890
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 891
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 894
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 895
5000 HOUR MAINTENANCE CHECKS 896
SECTION P3 – LINCOLN AUTOMATIC LUBRICATION SYSTEM – INDEX 897
LINCOLN AUTOMATIC LUBRICATION SYSTEM 899
System Components 899
System Operation 901
GENERAL INSTRUCTIONS 902
Lubricant Required for System 902
System Priming 902
SYSTEM CHECKOUT 902
24 VDC SOLID STATE TIMER CHECK 903
24 VDC Solid State Timer Adjustment 903
INJECTORS (SL-1 Series “H”) 904
Injector Specifications 904
Injector Adjustment 904
INJECTOR OPERATION 905
PUMP CYCLE TIMER (FLASHER TIMER) 906
Pump Cycle Timer (Flasher Timer) Installation 906
Pump Cycle Timer (Flasher Timer) Adjustment: 906
Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (N C ) 906
PRESSURE REDUCER ADJUSTMENT 908
TROUBLESHOOTING CHART 909
Preventative Maintenance Procedures 912
Daily Lubrication System Inspection 912
250 Hour Inspection 912
SECTION Q ALPHABETICAL INDEX 913
SECTION R – SYSTEM SCHEMATICS – INDEX 917
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH348 919
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH351 920
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH347 921
ENGINE RUN AND START ELECTRICAL SCHEMATIC – HE460 922
ELECTRICAL WIRING SCHEMATIC – EH0421 923

DESCRIPTION:

Komatsu 930E-2 Dump Truck Shop Manual CEBM006402 – PDF DOWNLOAD 

SERIAL NUMBERS A30156 thru A30180
w/ MTU/DDC 4000 Engine

FOREWORD:

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
• This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”,
  “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have 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.
  To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
  includes all accessories, body liners, tailgates, etc.) and then weigh truck.Record this value and subtract from the GVW rating.

S.V 12/12/24