Komatsu 930E-2 DUMP TRUCK Shop Manual CEBM006602 – PDF DOWNLOAD

Description

Komatsu 930E-2 DUMP TRUCK Shop Manual CEBM006602 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-2 DUMP TRUCK Shop Manual CEBM006602 – PDF DOWNLOAD

Language : English
Pages :994
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 930E-2 DUMP TRUCK Shop Manual CEBM006602 – PDF DOWNLOAD

SERIAL NUMBERS A30224 thru A30245

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.

TABLE OF CONTENTS:

Komatsu 930E-2 DUMP TRUCK Shop Manual CEBM006602 – PDF DOWNLOAD

SERIAL NUMBERS A30224 thru A30245

MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – TRUCK COMPONENTS AND SPECIFICATIONS 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 SYSTEM100
FUEL RECEIVER100
TANK BREATHER VALVE100
Removal100
Installation100
Disassembly100
Assembly100
LEFT SIDE FILL101
SECTION C – ENGINE – INDEX103
SECTION C2 – POWER MODULE – INDEX105
POWER MODULE107
Preparation107
Preparation for Removal108
Removal – Power Module111
Installation – Power Module113
Hookup – Power Module113
SECTION C3 – COOLING SYSTEM – INDEX115
COOLING SYSTEM117
RADIATOR117
Removal – Radiator117
RADIATOR REPAIR119
Internal Inspection119
External Cleaning119
Disassembly120
Cleaning and Inspection121
Assembly121
Pressure Testing122
Additional Service Information122
Installation – Radiator123
RADIATOR FILLING PROCEDURE124
COOLANT SYSTEM TROUBLESHOOTING124
SECTION C4 – POWERTRAIN – INDEX125
POWER TRAIN127
ALTERNATOR127
Removal – Alternator127
ENGINE/ALTERNATOR MATING129
General Instructions129
Measuring Procedure129
Joining The Alternator and Engine131
ENGINE132
Removal132
Service132
Installation132
SECTION C5 – AIR CLEANERS – INDEX133
AIR CLEANERS135
AIR CLEANERS135
Operation135
General Service Information135
FILTER ELEMENT REPLACEMENT136
Main Filter Element Cleaning137
Precleaner Section138
Cleaning Precleaner Tubes138
AIR INTAKE TROUBLESHOOTING139
SECTION C7 – FAN CLUTCH – INDEX141
FAN CLUTCH143
REMOVAL & INSTALLATION TOOLING143
FAN CLUTCH – DISASSEMBLY146
CLEANING AND INSPECTION156
ASSEMBLY – FAN CLUTCH160
TEST PROCEDURE174
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX175
SECTION D2 – 24 VDC ELECTRIC SUPPLY SYSTEM – INDEX177
24VDC ELECTRIC SUPPLY SYSTEM179
ELECTRICAL SYSTEM DESCRIPTION179
BATTERIES179
Maintenance and Service179
Troubleshooting179
BATTERY SUPPLY SYSTEM181
24VDC Battery Charging Alternator181
Battery Box181
Battery Control Box181
System Battery Starter Disconnect Relay181
Battery Disconnect Switches182
24VDC Auxiliary Battery Connectors182
Battery Equalizer183
Troubleshooting183
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX185
24 VDC ELECTRICAL SYSTEM COMPONENTS187
PASSENGER SEAT BASE COMPARTMENT187
TRUCK SHUTDOWN PROCEDURE187
COMPONENTS187
Tail Light Resistor Diode Assemblies187
5 Minute Idle Timer Components187
5 Minute Idle Timer189
5 Minute Idle Relay189
5 Minute Idle Contactor189
5 Minute Idle Circuit Test189
Inclinometer189
Brake Warning Buzzer (BWB)189
Alarm Indicating Device (AID) System189
Coolant Level/Flasher189
Temperature and Latch Card190
Hot Switch Inverter Card190
Hot Switch Inverter Card (Slot 4) (Not Used)191
Oil Level Card191
Temperature Card191
Diode Matrix (Without Sound) Card191
Diode Matrix (With Sound) Card191
Lamp Test Switch191
Electrical Interface Cabinet192
Lubrication System Timer192
Lincoln Lube Delay Timer192
Barometric Pressure Transducer192
Pulse Voltage Modulator192
Power Distribution Terminals192
Truck Control Interface Panel192
Kontrol Power Relay192
Circuit Breaker Panel192
Diode Board – DB1194
Diode Testing194
Relay Boards195
Relay Boards: RB1, RB2, RB3, RB4, RB5195
Service195
Relay Board Identification196
Relay Board Functions197
Installing Additional Circuits198
Body Up Switch199
Operation199
Adjustment199
Service199
Hoist Limit Switch200
Operation200
Adjustment200
Service200
CIRCUIT BREAKER CHART201
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX203
BATTERY CHARGING ALTERNATOR205
ELECTRICAL SYSTEM DESCRIPTION205
BATTERY205
Maintenance and Service205
Troubleshooting205
BATTERY CHARGING SYSTEM (Niehoff)207
General Description207
TROUBLESHOOTING PROCEDURES (On-Truck)207
Equipment Required:207
Preliminary Checks208
Test Setup208
Test Procedure208
Regulator Bypass Test209
ON VEHICLE TROUBLESHOOTING GUIDE211
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage211
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:211
CHARGE VOLT AND AMP VALUES212
DEFINITIONS212
ADVANCED SYSTEM TROUBLESHOOTING213
Static Test – Engine OFF, Key ON, Battery Switch ON213
Go To Alternator213
Go To Regulator (If Required)214
Go To Regulator Connector On The Alternator214
ALTERNATOR OVERHAUL215
ALTERNATOR DIMENSIONS215
ALTERNATOR SPECIFICATIONS216
SERVICE PARTS217
ON-VEHICLE TEST219
Equipment:219
Preliminary Checks:219
Test Set-up219
Test Procedure219
ON-VEHICLE TEST220
Bypass Test:220
BENCH TEST221
STATIC TESTS222
Regulator Tests222
Control Box Tests223
ALTERNATOR DISASSEMBLY225
ASSEMBLY- ALTERNATOR230
BF4822 STATOR SERVICE TOOL INSTRUCTIONS239
Stator Removal And Replacement239
Stator Installation240
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX243
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX245
ELECTRICAL PROPULSION SYSTEM COMPONENTS247
GENERAL SYSTEM DESCRIPTION247
SYSTEM COMPONENTS249
Auxiliary Blower System249
Propulsion System Controller (PSC)249
TRUCK CONTROL INTERFACE PANEL (TCI)250
Diagnostic Information Display251
DID PANEL EVENT CODES251
PSC SOFTWARE FUNCTIONS276
Input Processing276
STATE MANAGEMENT276
State Machine276
Transitions Between States277
DC Link State279
Powering the Link279
De-Powering the Link279
Control Functions279
Engine Control279
ALTERNATOR FIELD CONTROL280
Desired Three-Phase Voltage280
Desired DC Link Voltage280
Self-load280
Propel Torque Control281
Retard Torque Control281
Wheel Slide Control281
Resistor Grid Control282
Chopper Voltage Control282
AUXILIARY BLOWER CONTROL282
EVENT PROCESSING282
Event Detection282
Power On Tests282
Initiated Tests283
Periodic Tests283
EVENT RESTRICTIONS283
EVENT LOGGING AND STORAGE283
Event History Buffer284
Data Packs284
To Record and Save a Data Pack to a Floppy Disk284
Event Reset285
SERIAL DATA COMMUNICATIONS286
PSC – TCI Communications processing286
PSC – PTU Communications Processing286
Inverter Communications Processing286
OUTPUT PROCESSING287
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS287
Fast Start287
Engine Shutdown/Engine Not Running287
Limp Home Mode287
Entering/Exiting Limp Home Mode287
PROPULSION SYSTEM COMPONENT ABBREVIATIONS288
ELECTRONIC ACCELERATOR AND RETARD PEDALS298
Removal298
Installation298
Disassembly298
Assembly298
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX299
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE301
AC DRIVE SYSTEM MAINTENANCE301
TRUCK SHUTDOWN PROCEDURES301
NORMAL TRUCK SHUTDOWN PROCEDURE302
SHUTDOWN AFTER SYSTEM FAILURE303
SYSTEM CHECKOUT304
Battery and Control Checks of System WITH Battery Power OFF304
Battery and Control Circuit Checks of System With Battery Power ON307
Checks with Key Switch OFF308
CPU Battery Checks310
MEMORY BACKUP BATTERY REPLACEMENT310
TCI PROGRAMMING311
PSC PROGRAMMING311
INVERTER PROGRAMMING312
TCI CHECKOUT312
Modular Mining Communication Port313
TCI Input Checks314
TCI Digital Output Tests316
TCI Digital Input Tests318
PSC Checkout Procedure320
PSC Digital Input Checks324
Miscellaneous Checks325
A3PV Panel325
LINKV Panel325
Thermistor Checks325
17FM384 Panel Check325
Pedal Percentages and Meter Calibration326
Meter Calibration Procedure326
Reprogram With Serial Numbers and Pedal Percentages328
LOAD TESTING330
Preload Checks330
ADDITIONAL TRUCK CHECKS332
On-Board Load Testing334
Preparation334
Initiate Loadbox Test337
Manual Offset HP Output Adjustment339
TROUBLESHOOTING341
PVM Optimum Load Curve Handshaking Troubleshooting341
MISCELLANEOUS COMPONENT REPAIR342
Troubleshooting Phase Modules and Chopper Modules342
Phase Module Removal and Snubber Resistor Replacement342
Snubber Resistor Installation343
Phase Module Installation343
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING344
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING347
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING348
IGBT TROUBLESHOOTING349
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX351
SECTION G2 – TIRES AND RIMS – INDEX353
TIRES AND RIMS355
WHEEL STUD MAINTENANCE356
FRONT TIRES AND RIMS357
Removal357
Installation358
REAR TIRES AND RIMS359
Removal359
Installation360
RIM361
Tire Removal361
Tire Installation362
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX365
FRONT WHEEL HUB AND SPINDLE367
WHEEL HUB AND SPINDLE ASSEMBLY367
Preparation367
Removal367
Installation – Wheel Hub and Spindle Assembly370
Disassembly – Wheel Hub and Spindle Assembly371
Cleaning and Inspection – Wheel Hub and Spindle Assembly371
Assembly – Wheel Hub and Spindle Assembly373
Wheel Bearing Adjustment:373
Brake Installation374
Seal Assembly Gap Check375
STEERING CYLINDERS AND TIE ROD376
Spherical Bearing Wear Limits376
Removal – Steering Cylinder and Tie Rod377
Installation – Steering Cylinder and Tie Rod378
Bearing Replacement378
TOE-IN ADJUSTMENT379
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX381
REAR AXLE HOUSING ATTACHMENT383
PIVOT PIN383
Removal383
Installation383
PIVOT EYE BEARING384
Disassembly384
Assembly384
PIVOT EYE REPAIR385
Removal385
Disassembly385
Assembly385
Installation385
ANTI-SWAY BAR386
Removal386
Installation386
Disassembly386
Cleaning and Inspection386
Assembly386
SECTION G5 – REAR AXLE HOUSING – INDEX387
REAR AXLE HOUSING389
REAR AXLE HOUSING389
Preparation389
Removal389
Cleaning and Inspection – Rear Axle Housing391
Installation – Rear Axle Housing391
WHEEL MOTOR392
Preparation392
Removal392
Cleaning and Inspection – Wheel Motor393
Installation – Wheel Motor394
WHEEL MOTOR GEAR OIL397
Filtering Requirements397
Particle Size Analysis397
Flushing397
Oil Sample Analysis398
ELEMENT SPECIFICATION CHARTS399
SECTION H – HYDRAIR II SUSPENSIONS – INDEX403
SECTION H2 – FRONT SUSPENSIONS – INDEX405
FRONT SUSPENSION407
Removal407
Installation – Front Suspension408
“Turn-Of-The-Nut” Tightening Procedure411
MINOR REPAIRS (LOWER BEARING & SEALS)412
Removal – Bearing Retainer412
Installation – Bearing Retainer412
MAJOR SUSPENSION REBUILD414
Disassembly414
Assembly414
SECTION H3 – REAR SUSPENSIONS – INDEX417
REAR SUSPENSIONS419
Removal419
Installation – Rear Suspension421
Disassembly – Rear Suspension422
Cleaning and Inspection – Rear Suspension422
Assembly – Rear Suspension422
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX425
SUSPENSION OILING AND CHARGING PROCEDURE427
GENERAL427
EQUIPMENT LIST427
Hydrair® Charging Kit427
Installation of Charging Kit427
Removal of Charging Kit428
Support Blocks For Oiling And Charging Dimensions428
FRONT SUSPENSION429
Front Suspension Oiling429
Front Suspension Nitrogen Charging430
REAR SUSPENSION431
Rear Suspension Oiling431
Rear Suspension Nitrogen Charging432
OIL AND NITROGEN SPECIFICATIONS CHART434
SECTION J – BRAKE CIRCUIT – INDEX435
SECTION J2 – BRAKE CIRCUIT – INDEX437
BRAKE CIRCUIT439
SERVICE BRAKE CIRCUIT439
SECONDARY BRAKING AND AUTOMATIC APPLY441
PARKING BRAKE CIRCUIT441
BRAKE LOCK CIRCUIT442
WARNING CIRCUIT442
Rear Axle Brake Lines444
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX445
BRAKE CIRCUIT COMPONENT SERVICE447
BRAKE VALVE447
Rebuild Criteria447
Removal448
Installation448
DISASSEMBLY449
Cleaning and Inspection452
ASSEMBLY452
Actuator Base Threaded Inserts452
Boot and Cap452
Valve Body Seal Installation452
Regulator Sleeve O-ring Installation453
Actuator Plunger O-ring Installation453
Assembly of Valve453
DIFFERENTIAL PRESSURE SWITCH455
Disassembly455
Cleaning and Inspection455
Assembly455
VALVE BENCH TEST AND ADJUSTMENT456
Test Set Up Procedure457
Brake Valve Output Pressure Adjustment457
Differential Pressure Switch Adjustment457
Final Test and Adjustment458
Installation Of Brake Pedal Actuator Assembly to Brake Valve459
Installation of Retard Pedal To Brake Pedal459
DUAL RELAY VALVE461
Removal461
Installation461
Disassembly463
Cleaning and Inspection463
Assembly463
DIFFERENTIAL PRESSURE SWITCH464
Disassembly464
Cleaning and Inspection464
Assembly464
VALVE TEST AND ADJUSTMENT465
Test Set Up Procedure466
Brake Valve Output Pressure Adjustment466
Differential Pressure Switch Adjustment467
BRAKE MANIFOLD468
Removal468
Installation469
Disassembly469
Cleaning and Inspection469
Assembly469
HYDRAULIC BRAKE ACCUMULATORS470
Brake Accumulator Bleed Down Procedure470
ACCUMULATORS – HYDRAULIC COMPONENT CABINET470
Removal470
Installation470
Disassembly470
Cleaning and Inspection472
Assembly472
BLADDER ACCUMULATOR CHARGING PROCEDURE474
Temperature During Precharge475
Precharge Maintenance475
Accumulator Storage Procedures476
Bladder Storage Procedures477
ACCUMULATORS – FRAME MOUNTED477
Removal477
Installation477
Disassembly479
Cleaning and Inspection479
Assembly – Accumulator480
Accumulator Testing480
ACCUMULATOR CHARGING PROCEDURE481
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)482
Removal482
Installation482
Disassembly and Adjustment482
Potentiometer Check484
Assembly484
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX485
BRAKE CIRCUIT CHECK-OUT PROCEDURE487
EQUIPMENT REQUIRED489
INITIAL SYSTEM SET-UP490
BRAKE SYSTEM CHECKOUT491
Failure Modes Check-Out492
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING495
CHECK-OUT PROCEDURE499
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX501
WET DISC BRAKE ASSEMBLY503
OPERATION503
MAINTENANCE504
Brake Disc Wear Indicator504
Removal/Installation – Wet Disc Brake Assembly504
BRAKE REBUILD506
Disassembly506
Cleaning and Inspection509
Assembly510
Floating Ring Seal Assembly/Installation513
WET DISC BRAKE BLEEDING PROCEDURE516
SECTION J7 – PARKING BRAKE – INDEX517
PARKING BRAKE519
OPERATION519
MAINTENANCE520
Inspection – Parking Brake520
Removal – Parking Brake520
Installation – Parking Brake521
Disassembly – Parking Brake522
Cleaning and Inspection – Parking Brake522
Assembly – Parking Brake522
PARKING BRAKE BLEEDING PROCEDURE524
SECTION L – HYDRAULIC SYSTEM – INDEX525
SECTION L2 – HYDRAULIC SYSTEM – INDEX527
HYDRAULIC SYSTEM529
Hoist Circuit Operation530
Steering Circuit Operation532
Disc Brake Cooling System534
SECTION L3 – HYDRAULIC SYSTEM COMPONENTS REPAIR – INDEX537
HYDRAULIC SYSTEM COMPONENT REPAIR539
HOIST PUMP539
Removal539
Installation541
Disassembly542
Inspection of Parts546
Assembly546
TROUBLESHOOTING GUIDE (HOIST PUMP)551
HYDRAULIC TANK552
Filling Instructions552
Removal – Hydraulic Tank552
Installation – Hydraulic Tank553
HYDRAULIC TANK STRAINERS553
Removal553
Inspect and Clean553
Installation553
HYDRAULIC TANK BREATHERS554
SECTION L4 – STEERING CIRCUIT – INDEX555
STEERING CIRCUIT557
STEERING CIRCUIT OPERATION557
COMPONENT DESCRIPTION558
Steering Control Unit558
Bleeddown Manifold Valve559
Bleeddown Solenoid559
Relief Valves561
Hoist Limit Solenoid561
Accumulators561
Low Precharge Warning Switch561
High Pressure Filters561
Quick Disconnect Ports561
Flow Amplifier562
FLOW AMPLIFIER SYSTEM OPERATION564
No Steer564
Steering Left566
Steering Right568
No Steer, External Shock Load570
STEERING PUMP572
Operation572
High Altitude Operation572
PRINCIPLE OF OPERATION574
Full Pump Volume574
Half Pump Volume574
Neutral Position574
ADDITIONAL STEERING PUMP INFORMATION575
SECTION L5 – STEERING CONTROL UNIT – INDEX577
STEERING CONTROL UNIT579
Removal579
Installation579
STEERING CONTROL UNIT REBUILD580
Disassembly580
Cleaning and Inspection – Steering Control Unit581
Assembly – Steering Control Unit583
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX587
STEERING CIRCUIT COMPONENT REPAIR589
BLEEDDOWN MANIFOLD VALVE589
Removal589
Installation589
ACCUMULATORS590
Removal590
Installation590
Disassembly – Accumulators591
Cleaning and Inspection – Accumulators591
Assembly – Accumulators592
Testing – Accumulators592
STEERING ACCUMULATOR CHARGING PROCEDURE593
FLOW AMPLIFIER594
Removal594
Installation594
FLOW AMPLIFIER REBUILD594
Disassembly – Flow Amplifier596
Assembly – Flow Amplifier597
STEERING CYLINDERS598
Disassembly – Steering Cylinder599
Piston Seal & Bearing Installation599
Assembly – Steering Cylinder599
Test – Steering Cylinder599
STEERING AND BRAKE PUMP600
Removal600
Installation600
Disassembly – Steering and Brake Pump602
Control Piston Group602
Valve Plate Group602
Rotating Group605
Swashblock Group605
Driveshaft Group605
Inspection – Steering and Brake Pump605
Control Piston Group605
Valve Plate Group605
Rotating Group605
Swashblock Group607
Driveshaft Group608
Compensator Block and Unloader Module608
Stroke Adjuster Assembly608
Assembly – Steering and Brake Pump608
Swashblock Group608
Driveshaft Group609
Rotating Group609
Control Piston Group609
Valve Plate Group610
TROUBLESHOOTING CHART611
SECTION L7 – HOIST CIRCUIT – INDEX617
HOIST CIRCUIT619
HOIST CIRCUIT OPERATION619
COMPONENT DESCRIPTION620
Hydraulic Tank620
Hydraulic Pump620
High Pressure Filters620
Hoist Valve620
Inlet Sections – Hoist Valve620
Spool Sections – Hoist Valve621
Hoist Pilot Valve621
Bleeddown Manifold622
Hoist-up Limit Solenoid622
Pilot Operated Check Valve622
Overcenter Manifold622
HOIST CIRCUIT OPERATION623
Float Position Of Pilot Valve With Truck Body On Frame624
Power Up Operation626
Hold Operation628
Power Down Operation630
Float Operation632
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX635
HOIST CIRCUIT COMPONENT REPAIR637
HOIST VALVE637
Removal – Hoist Valve637
Installation – Hoist Valve638
O-Ring Replacement638
INLET SECTION639
Disassembly – Inlet Section639
Cleaning and Inspection – Inlet Section640
Assembly – Inlet Section640
REAR SPOOL SECTION (Work Ports)640
Disassembly – Rear Spool Section640
Cleaning and Inspection – Rear Spool Section642
Assembly – Rear Spool Section642
FRONT SPOOL SECTION (Tank Ports)643
Disassembly643
Cleaning and Inspection643
Assembly643
HOIST PILOT VALVE645
Removal – Hoist Pilot Valve645
Installation – Hoist Pilot Valve645
Disassembly – Hoist Pilot Valve646
Cleaning and Inspection – Hoist Pilot Valve647
Assembly – Hoist Pilot Valve647
HOIST CYLINDERS648
Removal – Hoist Cylinder648
Installation – Hoist Cylinder649
Disassembly – Hoist Cylinder651
Cleaning and Inspection – Hoist Cylinder652
Assembly – Quill And Cylinder653
Installation – Quill653
Installation – Check Balls And Plugs In Quill654
Assembly – Hoist Cylinder655
DISABLED TRUCK DUMPING PROCEDURE656
Hookup656
DUMPING PROCEDURE656
Raising the Body656
Lowering the Body656
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX657
HYDRAULIC SYSTEM FILTERS659
HOIST CIRCUIT FILTER659
Filter Element Replacement659
Removal – Hoist Circuit Filter660
Installation – Hoist Circuit Filter660
Indicator Switch – Hoist Circuit Filter660
STEERING CIRCUIT FILTER661
Filter Element Replacement661
Removal – Steering Circuit Filter662
Installation – Steering Circuit Filter662
Indicator Switch – Steering Circuit Filter662
INDICATOR SWITCH662
Test Procedure662
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX665
HYDRAULIC CHECK-OUT PROCEDURE667
GENERAL INFORMATION667
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE667
Equipment Requirements668
Pump Pressure Control Adjustments668
Steering Control Unit and Flow Amplifier Leakage Test669
Bleeddown Manifold Leakage Test669
Steering/Brake Pump Stroke Adjustment670
Shock And Suction Valves671
Equipment Requirements671
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES672
Equipment Requirements672
Pressure Checks672
Brake Cooling Circuit Test672
Power Up Relief Pressure Test673
Adjustment673
Power Down Relief Pressure Test674
Adjustment674
Hoist Counterbalance Valve Adjustment Preparation675
Counterbalance Valve Pressure Check675
Counterbalance Valve Adjustment676
HYDRAULIC SYSTEM FLUSHING PROCEDURE677
Preparation677
Flushing Procedure677
Filter Element Replacement678
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET679
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET680
SECTION M – OPTIONS AND SPECIAL TOOLS – INDE681
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX683
FIRE CONTROL SYSTEM (MANUAL)685
Operation685
Inspection and Maintenance685
Recharging Procedures686
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1687
Control Module687
Actuator688
Linear Detection Wire688
Power Wire688
Test Kit688
Squib688
Securing the Detection Wire689
Preliminary Test Before Final Hook-Up689
Installation Procedure for Squib691
Placing the Electric Detection & Actuation System Into Service691
INSPECTION AND MAINTENANCE SCHEDULES692
Daily692
Normal Maintenance Based On Actual Operating Hours692
IN CASE OF FIRE693
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM695
SECTION M8 – SPECIAL TOOLS697
SECTION M20 – PAYLOAD METER II – ON BOARD WEIGHING INDEX703
GENERAL INFORMATION705
Haul Cycles705
LIGHTS, SWITCHES AND COMPONENTS706
TIPS FOR OPERATION707
EXTERNAL DISPLAY LIGHTS707
THEORY OF OPERATION708
Basic Description708
Inclinometer708
Linkage Factor708
Gain Factor709
Brake Lock709
Sources of Error709
Typical Data From Service Check Mode709
Example Calculation of Payload710
Viewing Payload Calculation Inputs710
Checking the Gain711
Adjusting the Gain711
TYPES OF DATA STORED712
Cycle Data712
Engine ON/OFF Data713
Fault Codes and Warning Data713
Engine Operation714
Total Payload and Total Number of Cycles714
Other Data714
OPERATOR FUNCTIONS715
Using the Operator Load Counter715
Viewing the Operator Load Counter715
Clearing the Operator Load Counter715
Dimming the Lights on the Display715
INITIAL SETUP OF PAYLOAD METER716
Switch Settings716
Checking the Operator Check Mode717
Checking the Service Check Mode717
Checking the Gt setting:718
Checking the Inclinometer Settings718
Calibrating a Truck718
DISPLAYS AT START-UP719
Normal Operation719
SETUP AND MAINTENANCE720
Setting The Speed Limit720
Setting the Option Code720
Setting The Machine ID Code721
Setting The Operator ID Code721
Setting The Time and Date721
DOWNLOAD OF INFORMATION722
DISPLAY OF FAULT CODES722
Monitoring Input Signals726
Service Check Mode726
UP FACTOR – PAYLOAD CALCULATION GAIN727
PL MODE -LOAD CALCULATION TIMING727
FINAL GEAR RATIO SELECTION728
BATTERY REPLACEMENT PROCEDURE729
Replacing the Battery729
After Replacing the Battery730
SUSPENSION PRESSURE SENSOR730
Removal730
Installation731
INCLINOMETER731
Removal731
Installation731
Adjustment731
PAYLOAD METER BACK PANEL732
CONNECTIONS733
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE734
PAYLOAD CIRCUIT NUMBERS735
TROUBLESHOOTING736
COMMON PROBLEMS736
Suspension Charging736
Symptom Table737
Missing Body-Up Signal737
Missing Speed Signal738
F-18: Alternator R-Terminal, Oil Pressure Signals738
Shorted 18v Sensor Power Supply (930E)738
FAULT TREE DIAGNOSIS739
Payload Lights Won’t Illuminate739
Red, Amber or Green Payload Light Does Not Illuminate740
Cannot Download – PC Communications741
PC Communications Configuration742
FCAL: Payload Meter Won’t Calibrate743
F-20: Sensor Power Fault744
F-21, F-25: Left Front Pressure Sensor746
F-22, F-26: Right Front Pressure Sensor746
F-23, F-27: Left Rear Pressure Sensor746
F-24, F-28: Right Rear Pressure Sensor746
F-31, F-32: Inclinometer748
Body Up Input750
Brake Lock Input751
Speed Signal752
Adjusting the Speed Sensor752
CONNECTORS AND PRESSURE SENSORS754
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM757
Menu Functions760
Using Scope760
Log File Information760
Connections to Payload Meter II™761
USING SCOPE762
Monitoring Inputs Using Scope762
Monitoring Suspension Charging Using Scope762
Pressure Sensor Dummy Loads765
GAIN ADJUSTMENT WORKSHEET766
SECTION N – CAB COMPONENTS – INDEX767
SECTION N2 – TRUCK CAB – INDEX769
TRUCK CAB771
Description771
Preparation772
Removal – Cab772
Installation – Cab774
CAB DOOR774
Removal774
Installation774
Door Adjustment775
Door Jamb Bolt Adjustment775
Door Handle Plunger Adjustment776
Door Glass Replacement777
Door Window Regulator Replacement781
Door Handle or Latch Assembly Replacement781
Door and Door Hinge Seal Replacement782
Door Opening Seal Removal782
Installation782
GLASS REPLACEMENT783
Adhesive Bonded Windows783
Replacement Procedure783
Windshield And Rear Glass784
Removal784
Installation785
SECTION N3 – CAB COMPONENTS – INDEX787
CAB COMPONENTS789
WINDSHIELD WIPERS789
Wiper Motor Replacement789
Removal789
Installation789
Wiper Arm Replacement789
Removal789
Installation790
Wiper Linkage Replacement790
Removal790
Installation790
WINDSHIELD WASHER791
Operation791
Service791
OPERATOR SEAT792
Adjustment792
Removal792
Installation792
SECTION N4 – OPERATOR COMFORT – INDEX793
OPERATOR COMFORT795
HEATER/AIR CONDITIONER795
Operation795
HEATER COMPONENTS796
Circuit Breakers796
Heater Control Components796
Heater Coil796
Fan Motor And Speed Control797
Actuators797
Filter Service797
AIR CONDITIONING SYSTEM799
Environmental Impact799
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES800
PRINCIPLES OF REFRIGERATION800
Air Conditioning800
Refrigeration – The Act Of Cooling801
The Refrigeration Cycle801
AIR CONDITIONER SYSTEM COMPONENTS802
Compressor (Refrigerant Pump)802
Service Valves802
Condenser802
Receiver-Drier802
Expansion Block Valve803
Accumulator803
Evaporator803
ELECTRICAL CIRCUIT804
Thermostat804
Compressor Clutch804
Trinary™ Switch805
SYSTEM SERVICING806
SERVICE TOOLS AND EQUIPMENT807
Recovery/Recycle Station807
Leak Detector807
Service Valves808
Vacuum Pump808
Manifold Gauge Set809
Installing Manifold Gauge Set810
Purging Air From Service Hoses810
SYSTEM PERFORMANCE TEST811
SYSTEM OIL812
Handling and Reusing PAG Oil812
Oil Quantity812
Checking System Oil812
REFRIGERANT813
Recycled Refrigerant813
Reclaimed Refrigerant813
Refrigerant Quantity813
R-134a Refrigerant Containers813
SYSTEM LEAK TESTING814
Electronic Leak Detector814
Tracer Dyes814
Soap and Water814
RECOVERING AND RECYCLING THE REFRIGERANT815
Performing the Recovery Cycle815
Performing the Recycling Procedure815
Evacuating and Charging the A/C System815
SYSTEM REPAIR816
System Flushing816
COMPONENT REPLACEMENT816
Hoses and Fittings816
Lines816
Expansion Valve817
Receiver-Drier817
Thermostat817
Compressor817
Accumulator817
Clutch818
Servicing the Compressor Clutch818
Pulley Removal820
Clutch Coil Check821
Pulley Installation821
Clutch Assembly Installation821
EVACUATING THE SYSTEM823
CHARGING THE A/C SYSTEM825
TROUBLESHOOTING826
Preliminary Checks826
Diagnosis Of Gauge Readings And System Performance826
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS827
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM833
SECTION N5 – OPERATOR CAB CONTROLS – INDEX835
OPERATOR CAB CONTROLS837
STEERING COLUMN837
Removal837
Installation837
STEERING WHEEL AND CONTROLS839
Horn Button839
Telescope Lock Ring839
Tilt Wheel Lever839
Turn Signal / Headlight Dimmer839
DYNAMIC RETARDING839
Retarder Control Lever840
Dynamic Retarder /Service Brake Pedal840
Accelerator (Throttle) Pedal840
Starting on a Grade With a Loaded Truck840
GRADE/SPEED RETARD CHART841
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS842
Defroster Control Switch842
Outside/Inside Air Control Switch842
Heat Vent Control Switch842
Temperature Control Knob842
Fan Control Knob842
Heater/Air Conditioner Selector Switch842
Heater/Air Conditioner Vents842
INSTRUMENT PANEL843
OVERHEAD PANEL AND DISPLAYS843
CENTER CONSOLE844
F-N-R Selector Switch844
Hoist Control Lever845
To Raise dump body:845
To lower body:845
Ash Tray845
Lighter845
LH Window Control Switch845
RH Window Control Switch845
Engine Shutdown Switch845
Override/Fault Reset Switch846
Retard Speed Control (RSC) “Off/On” Switch846
Retard Speed Control (RSC) Adjust Dial846
PSC Download Port847
Engine Diagnostics Download Port847
Engine Control System847
TCI Download Port847
Passenger Seat847
INSTRUMENT PANEL AND INDICATOR LIGHTS849
Control Symbols849
INSTRUMENT PANEL (Figure 5-6)849
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)851
Key Switch851
Starting851
Cold Weather Starting851
Normal Engine Shutdown851
Engine Shutdown Switch with 5 Minute Idle Timer Delay852
Operation852
Fog Lights (Optional)852
Ladder Light Switch852
Manual Backup Switch852
Panel Illumination Lights853
Cab Air Conditioner/Heater Vents853
Rotating Beacon Light Switch (Optional)853
Heated Mirror Switch (Optional)853
Wheel Brake Lock Control853
Parking Brake Control853
Tachometer854
Right Turn Signal Indicator854
High Beam Indicator854
Left Turn Signal Indicator854
Speedometer854
Voltmeter854
Engine Oil Pressure Gauge854
Water Temperature Gauge854
Fuel Gauge854
AC Drive System Temperature Gauge855
Hydraulic Oil Temperature Gauge855
Hourmeter855
Rest Switch855
Light Switch856
Windshield Wiper and Washer856
Panel Light Dimmer856
STATUS / WARNING INDICATOR LIGHT SYMBOLS858
Hazard Warning Lights863
Lamp Test Switch863
Link-On Warning Light863
SECTION P – LUBRICATION AND SERVICE -INDEX865
SECTION P2 – LUBRICATION AND SERVICE – INDEX867
LUBRICATION AND SERVICE869
930E SERVICE CAPACITIES869
HYDRAULIC TANK SERVICE869
Adding Oil869
WHEEL MOTOR SERVICE869
COOLANT LEVEL CHECK870
RADIATOR FILLING PROCEDURE870
RESERVE ENGINE OIL SYSTEM (Optional)870
Reserve Oil Tank Filling Procedure (Remote fill)870
LUBRICATION CHART871
10 HOUR (DAILY) INSPECTION872
50 HOUR LUBRICATION AND MAINTENANCE CHECKS875
100 HOUR LUBRICATION AND MAINTENANCE CHECKS876
250 HOUR LUBRICATION AND MAINTENANCE CHECKS877
500 HOUR LUBRICATION AND MAINTENANCE CHECKS880
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS881
5000 HOUR MAINTENANCE CHECKS882
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX883
AUTOMATIC LUBRICATION SYSTEM885
GENERAL DESCRIPTION885
SYSTEM COMPONENTS887
SYSTEM OPERATION888
Normal Operation888
Pressure Failure Detection Circuits889
INJECTOR OPERATION890
GENERAL INSTRUCTIONS891
LUBRICANT REQUIREMENTS891
System Priming891
LUBRICANT PUMP891
Pump Housing Oil Level891
Pump Pressure Control891
Pressure Control Valve Adjustment891
INJECTORS (SL-1 Series “H”))892
Injector Specifications892
Injector Adjustment892
SYSTEM CHECKOUT892
Lubrication Cycle Timer Check893
Lubrication Cycle Timer Adjustment893
FILTER ASSEMBLY893
PUMP REBUILD894
Disassembly894
Cleaning and Inspection894
Assembly896
SYSTEM TROUBLESHOOTING CHART897
PREVENTATIVE MAINTENANCE PROCEDURES900
Daily Lubrication System Inspection900
250 Hour Inspection900
1000 Hour Inspection900
SECTION Q ALPHABETICAL INDEX901
SECTION R905
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH351907
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH352908
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH347909
LIGHTING AND CONTROL WIRING – EJ2145910
ELECTRICAL WIRING SCHEMATIC – EJ2146926

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24