Komatsu 930E-2 Dump Truck Shop Manual CEBM010401 – PDF DOWNLOAD

Description

Komatsu 930E-2 Dump Truck Shop Manual CEBM010401 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-2 Dump Truck Shop Manual CEBM010401 – PDF DOWNLOAD

Language : English
Pages :915
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 930E-2 Dump Truck Shop Manual CEBM010401 – PDF DOWNLOAD

SERIAL NUMBERS A30121 – A30155
w/CUMMINS QSK-60 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.

TABLE OF CONTENTS:

SERIAL NUMBERS A30121 – A30155
w/CUMMINS QSK-60 Engine

Komatsu 930E-2 Dump Truck Shop Manual CEBM010401 – PDF DOWNLOAD

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 FILL100
SECTION C102
ENGINE102
INDEX102
SECTION C – ENGINE – INDEX102
SECTION C2 – POWER MODULE – INDEX104
POWER MODULE106
Preparation106
Preparation for Removal107
Removal – Power Module110
Installation – Power Module112
Hookup – Power Module112
SECTION C3 – COOLING SYSTEM – INDEX114
COOLING SYSTEM116
RADIATOR116
Removal – Radiator116
RADIATOR REPAIR118
Internal Inspection118
External Cleaning118
Disassembly119
Cleaning and Inspection120
Assembly120
Pressure Testing121
Additional Service Information121
Installation – Radiator122
RADIATOR FILLING PROCEDURE123
COOLANT SYSTEM TROUBLESHOOTING123
SECTION C4 – POWERTRAIN – INDEX124
POWER TRAIN126
ALTERNATOR126
Removal – Alternator126
ENGINE/ALTERNATOR MATING128
General Instructions128
Measuring Procedure128
Joining The Alternator and Engine130
ENGINE131
Removal131
Service131
Installation131
SECTION C5 – AIR CLEANERS – INDEX132
AIR CLEANERS134
AIR CLEANERS134
Operation134
General Service Information134
FILTER ELEMENT REPLACEMENT135
Main Filter Element Cleaning136
Precleaner Section137
Cleaning Precleaner Tubes137
AIR INTAKE TROUBLESHOOTING138
SECTION D174
ELECTRICAL SYSTEM (24VDC NON-PROPULSION)174
INDEX174
SECTION C7 – FAN CLUTCH – INDEX140
FAN CLUTCH142
REMOVAL AND INSTALLATION TOOLING142
FAN CLUTCH – DISASSEMBLY145
CLEANING AND INSPECTION155
ASSEMBLY – FAN CLUTCH159
TEST PROCEDURE173
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX174
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX176
24VDC ELECTRIC SUPPLY SYSTEM178
ELECTRICAL SYSTEM DESCRIPTION178
BATTERIES178
Maintenance and Service178
Troubleshooting178
BATTERY SUPPLY SYSTEM180
24VDC Battery Charging Alternator180
Battery Box180
Battery Control Box180
System Battery Starter Disconnect Relay180
Battery Disconnect Switches181
24VDC Auxiliary Battery Connectors181
Battery Equalizer182
Troubleshooting182
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX184
24 VDC ELECTRICAL SYSTEM COMPONENTS186
PASSENGER SEAT BASE COMPARTMENT186
TRUCK SHUTDOWN PROCEDURE186
COMPONENTS186
Tail Light Resistor Diode Assemblies186
5 Minute Idle Timer Components186
Inclinometer188
Brake Warning Buzzer (BWB)188
Alarm Indicating Device (AID) System188
ELECTRICAL INTERFACE CABINET191
Lubrication System Timer191
Barometric Pressure Transducer191
Special Interface Module191
Power Distribution Terminals191
Truck Control Interface Panel191
Control Power Relay191
Circuit Breaker Panel191
Diode Board – DB1193
Diode Testing193
RELAY BOARDS194
Relay Boards – RB1, RB2, RB3, RB4, RB5194
Service194
Relay Board Identification195
Relay Board Functions196
Relay Board 6 (RB6)197
BODY-UP SWITCH198
Operation198
Adjustment198
Service198
HOIST LIMIT SWITCH199
Operation199
Adjustment199
Service199
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX202
BATTERY CHARGING ALTERNATOR204
ELECTRICAL SYSTEM DESCRIPTION204
BATTERY204
Maintenance and Service204
Troubleshooting204
BATTERY CHARGING SYSTEM (Niehoff)206
General Description206
TROUBLESHOOTING PROCEDURES (On-Truck)206
Equipment Required:206
Preliminary Checks207
Test Setup207
Test Procedure207
Regulator Bypass Test208
ON VEHICLE TROUBLESHOOTING GUIDE210
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage210
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:210
CHARGE VOLT AND AMP VALUES211
DEFINITIONS211
ADVANCED SYSTEM TROUBLESHOOTING212
Static Test – Engine OFF, Key ON, Battery Switch ON212
Go To Alternator212
Go To Regulator (If Required)213
Go To Regulator Connector On The Alternator213
ALTERNATOR OVERHAUL214
ALTERNATOR DIMENSIONS214
ALTERNATOR SPECIFICATIONS215
SERVICE PARTS216
ON-VEHICLE TEST218
Equipment:218
Preliminary Checks:218
Test Set-up218
Test Procedure218
ON-VEHICLE TEST219
Bypass Test:219
BENCH TEST220
STATIC TESTS221
Regulator Tests221
Control Box Tests222
ALTERNATOR DISASSEMBLY224
ASSEMBLY- ALTERNATOR229
BF4822 STATOR SERVICE TOOL INSTRUCTIONS238
Stator Removal And Replacement238
Stator Installation239
SECTION E242
ELECTRICAL PROPULSION SYSTEM242
INDEX242
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX242
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX244
ELECTRICAL PROPULSION SYSTEM COMPONENTS246
GENERAL SYSTEM DESCRIPTION246
SYSTEM COMPONENTS248
Auxiliary Blower System248
Propulsion System Controller (PSC)248
TRUCK CONTROL INTERFACE PANEL (TCI)249
Diagnostic Information Display250
DID PANEL EVENT CODES250
PSC SOFTWARE FUNCTIONS275
Input Processing275
STATE MANAGEMENT275
State Machine275
Transitions Between States276
DC Link State278
Powering the Link278
De-Powering the Link278
Control Functions278
Engine Control278
ALTERNATOR FIELD CONTROL279
Desired Three-Phase Voltage279
Desired DC Link Voltage279
Self-load279
Propel Torque Control280
Retard Torque Control280
Wheel Slide Control280
Resistor Grid Control281
Chopper Voltage Control281
AUXILIARY BLOWER CONTROL281
EVENT PROCESSING281
Event Detection281
Power On Tests281
Initiated Tests282
Periodic Tests282
EVENT RESTRICTIONS282
EVENT LOGGING AND STORAGE282
Event History Buffer283
Data Packs283
To Record and Save a Data Pack to a Floppy Disk283
Event Reset284
SERIAL DATA COMMUNICATIONS285
PSC – TCI Communications processing285
PSC – PTU Communications Processing285
Inverter Communications Processing285
OUTPUT PROCESSING286
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS286
Fast Start286
Engine Shutdown/Engine Not Running286
Limp Home Mode286
Entering/Exiting Limp Home Mode286
PROPULSION SYSTEM COMPONENT ABBREVIATIONS287
ELECTRONIC ACCELERATOR AND RETARD PEDALS297
Removal297
Installation297
Disassembly297
Assembly297
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX298
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE300
AC DRIVE SYSTEM MAINTENANCE300
TRUCK SHUTDOWN PROCEDURES300
NORMAL TRUCK SHUTDOWN PROCEDURE301
SHUTDOWN AFTER SYSTEM FAILURE302
SYSTEM CHECKOUT303
Battery and Control Checks of System WITH Battery Power OFF303
Battery and Control Circuit Checks of System With Battery Power ON306
Checks with Key Switch OFF307
CPU Battery Checks309
MEMORY BACKUP BATTERY REPLACEMENT309
TCI PROGRAMMING310
PSC PROGRAMMING310
INVERTER PROGRAMMING311
TCI CHECKOUT311
Modular Mining Communication Port312
TCI Input Checks313
TCI Digital Output Tests315
TCI Digital Input Tests317
PSC Checkout Procedure319
PSC Digital Input Checks323
Miscellaneous Checks324
A3PV Panel324
LINKV Panel324
Thermistor Checks324
17FM384 Panel Check324
Pedal Percentages and Meter Calibration325
Meter Calibration Procedure325
Reprogram With Serial Numbers and Pedal Percentages327
LOAD TESTING329
Preload Checks329
ADDITIONAL TRUCK CHECKS331
On-Board Load Testing333
Preparation333
Initiate Loadbox Test336
Manual Offset HP Output Adjustment338
TROUBLESHOOTING340
PVM Optimum Load Curve Handshaking Troubleshooting340
MISCELLANEOUS COMPONENT REPAIR341
Troubleshooting Phase Modules and Chopper Modules341
Phase Module Removal and Snubber Resistor Replacement341
Snubber Resistor Installation342
Phase Module Installation342
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING343
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING346
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING347
IGBT TROUBLESHOOTING348
SECTION G350
REAR AXLE, SPINDLES AND WHEELS350
INDEX350
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX350
SECTION G2 – TIRES AND RIMS – INDEX352
TIRES AND RIMS354
WHEEL STUD MAINTENANCE355
FRONT TIRES AND RIMS356
Removal356
Installation357
REAR TIRES AND RIMS358
Removal358
Installation359
RIM360
Tire Removal360
Tire Installation361
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX364
FRONT WHEEL HUB AND SPINDLE366
WHEEL HUB AND SPINDLE ASSEMBLY366
Preparation366
Removal366
Installation – Wheel Hub and Spindle Assembly369
Disassembly – Wheel Hub and Spindle Assembly370
Cleaning and Inspection – Wheel Hub and Spindle Assembly370
Assembly – Wheel Hub and Spindle Assembly372
Wheel Bearing Adjustment:372
Brake Installation373
Seal Assembly Gap Check374
STEERING CYLINDERS AND TIE ROD375
Spherical Bearing Wear Limits375
Removal – Steering Cylinder and Tie Rod376
Installation – Steering Cylinder and Tie Rod377
Bearing Replacement377
TOE-IN ADJUSTMENT378
SECTION G4 – REAR AXLE HOUSING – INDEX380
REAR AXLE HOUSING ATTACHMENT382
PIVOT PIN382
Removal382
Installation382
PIVOT EYE BEARING383
Disassembly383
Assembly383
PIVOT EYE REPAIR384
Removal384
Disassembly384
Assembly384
Installation384
ANTI-SWAY BAR385
Removal385
Installation385
Disassembly385
Cleaning and Inspection385
Assembly385
SECTION G5 – REAR AXLE HOUSING – INDEX386
REAR AXLE HOUSING388
REAR AXLE HOUSING388
Preparation388
Removal388
Cleaning and Inspection – Rear Axle Housing390
Installation – Rear Axle Housing390
WHEEL MOTOR391
Preparation391
Removal391
Cleaning and Inspection – Wheel Motor392
Installation – Wheel Motor393
WHEEL MOTOR GEAR OIL396
Filtering Requirements396
Particle Size Analysis396
Flushing396
Oil Sample Analysis397
ELEMENT SPECIFICATION CHARTS398
SECTION H402
HYDRAIR® II SUSPENSIONS402
INDEX402
SECTION H – HYDRAIR II SUSPENSIONS – INDEX402
SECTION H2 – FRONT SUSPENSIONS – INDEX404
FRONT SUSPENSION406
Removal406
Installation – Front Suspension407
“Turn-Of-The-Nut” Tightening Procedure410
MINOR REPAIRS (LOWER BEARING & SEALS)411
Removal – Bearing Retainer411
Installation – Bearing Retainer411
MAJOR SUSPENSION REBUILD413
Disassembly413
Assembly413
SECTION H3 – REAR SUSPENSIONS – INDEX416
REAR SUSPENSIONS418
Removal418
Installation – Rear Suspension420
Disassembly – Rear Suspension421
Cleaning and Inspection – Rear Suspension421
Assembly – Rear Suspension421
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX424
SUSPENSION OILING AND CHARGING PROCEDURE426
GENERAL426
EQUIPMENT LIST426
Hydrair® Charging Kit426
Installation of Charging Kit426
Removal of Charging Kit427
Support Blocks For Oiling And Charging Dimensions427
FRONT SUSPENSION428
Front Suspension Oiling428
Front Suspension Nitrogen Charging429
REAR SUSPENSION430
Rear Suspension Oiling430
Rear Suspension Nitrogen Charging431
OIL AND NITROGEN SPECIFICATIONS CHART433
SECTION J434
BRAKE CIRCUIT434
INDEX434
SECTION J – BRAKE CIRCUIT – INDEX434
SECTION J2 – BRAKE CIRCUIT – INDEX436
BRAKE CIRCUIT438
SERVICE BRAKE CIRCUIT438
SECONDARY BRAKING AND AUTOMATIC APPLY440
PARKING BRAKE CIRCUIT440
BRAKE LOCK CIRCUIT441
WARNING CIRCUIT441
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX444
BRAKE CIRCUIT COMPONENT SERVICE446
BRAKE VALVE446
Rebuild Criteria446
Removal – Brake Valve447
Installation – Brake Valve447
Disassembly – Brake Valve448
Cleaning and Inspection – Brake Valve451
Assembly – Actuator Base Threaded Inserts451
Assembly – Boot and Cap451
Installation – Valve Body Seal451
Installation – Regulator Sleeve O-Ring452
Installation – Actuator Plunger O-ring452
Assembly – Brake Valve452
DIFFERENTIAL PRESSURE SWITCH454
Disassembly454
Cleaning and Inspection454
Assembly454
VALVE BENCH TEST AND ADJUSTMENT455
Test Set Up Procedure456
Adjustment – Brake Valve Output Pressure456
Adjustment – Differential Pressure Switch456
Final Test and Adjustment457
Installation – Brake Pedal Actuator Assembly to Brake Valve458
Installation – Retard Pedal To Brake Pedal458
DUAL RELAY VALVE460
Removal460
Installation460
Disassembly – Dual Relay Valve462
Cleaning and Inspection – Dual Relay Valve462
Assembly – Dual Relay Valve462
DIFFERENTIAL PRESSURE SWITCH463
Disassembly463
Cleaning and Inspection463
Assembly463
VALVE TEST AND ADJUSTMENT464
Test Set Up Procedure465
Adjustment – Brake Valve Output Pressure465
Adjustment – Differential Pressure Switch466
BRAKE MANIFOLD467
Removal467
Installation468
Disassembly468
Cleaning and Inspection468
Assembly468
HYDRAULIC BRAKE ACCUMULATORS469
Brake Accumulator Bleed Down Procedure469
ACCUMULATORS – HYDRAULIC COMPONENT CABINET469
Removal469
Installation469
Disassembly469
Cleaning and Inspection471
Assembly471
BLADDER ACCUMULATOR CHARGING PROCEDURE473
Temperature During Precharge474
Precharge Maintenance474
Accumulator Storage Procedures475
Bladder Storage Procedures476
ACCUMULATORS – FRAME MOUNTED476
Removal476
Installation476
Disassembly478
Cleaning and Inspection478
Assembly – Accumulator479
Accumulator Testing479
ACCUMULATOR CHARGING PROCEDURE480
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)481
Removal – Retarder Control Lever481
Installation – Retarder Control Lever481
Disassembly and Adjustment – Retarder Control Lever482
Potentiometer Check – Retarder Control Lever482
Assembly – Retarder Control Lever482
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX484
BRAKE CIRCUIT CHECK-OUT PROCEDURE486
EQUIPMENT REQUIRED488
INITIAL SYSTEM SET-UP489
BRAKE SYSTEM CHECKOUT490
Failure Modes Check-Out491
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING494
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET498
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX500
WET DISC BRAKE ASSEMBLY502
OPERATION502
MAINTENANCE503
Brake Disc Wear Indicator503
Removal/Installation – Wet Disc Brake Assembly503
BRAKE REBUILD505
Disassembly505
Cleaning and Inspection508
Assembly509
Floating Ring Seal Assembly/Installation512
WET DISC BRAKE BLEEDING PROCEDURE515
SECTION J7 – PARKING BRAKE – INDEX516
PARKING BRAKE518
OPERATION518
MAINTENANCE519
Inspection – Parking Brake519
Removal – Parking Brake519
Installation – Parking Brake520
Disassembly – Parking Brake521
Cleaning and Inspection – Parking Brake521
Assembly – Parking Brake521
PARKING BRAKE BLEEDING PROCEDURE523
SECTION L524
HYDRAULIC SYSTEM524
INDEX524
SECTION L – HYDRAULIC SYSTEM – INDEX524
SECTION L2 – HYDRAULIC SYSTEM – INDEX526
HYDRAULIC SYSTEM528
Hoist Circuit Operation529
Steering Circuit Operation531
Disc Brake Cooling System533
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX536
HYDRAULIC SYSTEM COMPONENT REPAIR538
HOIST PUMP538
Removal538
Installation540
Disassembly541
Inspection Of Parts545
Assembly545
TROUBLESHOOTING GUIDE550
HYDRAULIC TANK551
Filling Instructions551
Removal551
Installation552
HYDRAULIC TANK STRAINERS552
Removal552
Inspect and Clean552
Installation552
Hydraulic Tank Breathers553
SECTION L4 – STEERING CIRCUIT – INDEX554
STEERING CIRCUIT556
STEERING CIRCUIT OPERATION556
COMPONENT DESCRIPTION557
Steering Control Valve557
Bleeddown Manifold Valve558
Bleeddown Solenoids558
Accumulators559
Low Precharge Warning Switch559
High Pressure Filter559
Flow Amplifier559
FLOW AMPLIFIER SYSTEM OPERATION561
No Steer561
Steering Left563
Steering Right565
No Steer, External Shock Load567
STEERING PUMP569
Operation569
High Altitude Operation569
PRINCIPLE OF OPERATION571
Steering Pump572
SECTION L5 – STEERING CONTROL UNIT – INDEX574
STEERING CONTROL UNIT576
Removal576
Installation576
STEERING CONTROL UNIT REBUILD577
Disassembly577
Cleaning and Inspection – Steering Control Unit578
Assembly – Steering Control Unit580
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX584
STEERING CIRCUIT COMPONENT REPAIR586
BLEEDDOWN MANIFOLD VALVE586
Removal586
Installation586
ACCUMULATORS587
Removal587
Installation587
Disassembly588
Cleaning and Inspection588
Assembly589
TESTING589
STEERING ACCUMULATOR CHARGING PROCEDURE590
FLOW AMPLIFIER591
Removal591
Installation591
FLOW AMPLIFIER REBUILD591
Disassembly593
Assembly594
STEERING CYLINDERS595
Disassembly596
Piston Seal & Bearing Installation596
Cylinder Assembly596
Test596
STEERING AND BRAKE PUMP597
Removal597
Installation597
Disassembly599
Control Piston Group599
Valve Plate Group599
Rotating Group602
Swashblock Group602
Driveshaft Group602
Inspection602
Control Piston Group602
Valve Plate Group602
Rotating Group602
Swashblock Group604
Driveshaft Group605
Compensator Block and Unloader Module605
Stroke Adjuster Assembly605
Assembly605
Swashblock Group605
Driveshaft Group606
Rotating Group606
Control Piston Group606
Valve Plate Group607
TROUBLESHOOTING CHART608
SECTION L7 – HOIST CIRCUIT – INDEX614
HOIST CIRCUIT616
HOIST CIRCUIT OPERATION616
COMPONENT DESCRIPTION617
Hydraulic Tank617
Hydraulic Pump617
High Pressure Filters617
Hoist Valve617
Inlet Sections617
Spool Sections618
Work Ports (Rear) Spool Section618
Tank Ports (Front) Spool Section618
Hoist Pilot Valve618
Hoist Up Limit Solenoid619
Pilot Operated Check Valve619
Snubber Valve619
Counterbalance Valve619
HOIST CIRCUIT OPERATION619
POWER UP OPERATION (Figure 7-5)621
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX630
HOIST CIRCUIT COMPONENT REPAIR632
HOIST VALVE632
Removal632
Installation633
O-Ring Replacement633
INLET SECTION634
Disassembly634
Cleaning and Inspection635
Assembly635
REAR SPOOL SECTION (Work Ports)635
Disassembly635
Cleaning and Inspection637
Assembly637
FRONT SPOOL SECTION (Tank Ports)638
Disassembly638
Cleaning and Inspection638
Assembly638
HOIST PILOT VALVE640
Removal640
Installation640
Disassembly641
Cleaning and Inspection642
Assembly642
HOIST – UP LIMIT SOLENOID VALVE643
HOIST CYLINDERS643
Removal643
Installation644
Disassembly646
Cleaning and Inspection647
ASSEMBLY OF QUILL AND CYLINDER648
Quill Installation648
Installation Of Check Balls And Plugs In Quill649
Assembly of Cylinder650
DISABLED TRUCK DUMPING PROCEDURE651
HOOKUP651
DUMPING PROCEDURE651
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX652
HYDRAULIC SYSTEM FILTERS654
HOIST CIRCUIT FILTER654
Filter Element Replacement654
Removal – Hoist Circuit Filter655
Installation – Hoist Circuit Filter655
Indicator Switch – Hoist Circuit Filter655
STEERING CIRCUIT FILTER656
Filter Element Replacement656
Removal – Steering Circuit Filter657
Installation – Steering Circuit Filter657
Indicator Switch – Steering Circuit Filter657
INDICATOR SWITCH657
Test Procedure657
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX660
HYDRAULIC CHECK-OUT PROCEDURE662
GENERAL INFORMATION662
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE662
Equipment Requirements663
Pump Pressure Control Adjustments663
Steering Control Valve and Flow Amplifier Leakage Test664
Bleeddown Manifold Leakage Test664
Steering / Brake Pump Stroke Adjustment665
Shock And Suction Valves666
Equipment Requirements666
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES667
Equipment Requirements667
Pressure Checks667
Brake Cooling Circuit Test667
Power Up Relief Pressure Test668
Adjustment668
Power Down Relief Pressure Test669
Adjustment669
Hoist Counterbalance Valve Adjustment670
HYDRAULIC SYSTEM FLUSHING PROCEDURE671
Preparation671
Flushing Procedure671
Filter Element Replacement672
930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET674
SECTION M676
OPTIONS AND SPECIAL TOOLS676
INDEX676
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX676
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX678
FIRE CONTROL SYSTEM (MANUAL)680
Operation680
Inspection and Maintenance680
Recharging Procedures681
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1682
Control Module682
Actuator683
Linear Detection Wire683
Power Wire683
Test Kit683
Squib683
Securing the Detection Wire684
Preliminary Test Before Final Hook-Up684
Installation Procedure for Squib686
Placing the Electric Detection & Actuation System Into Service686
INSPECTION AND MAINTENANCE SCHEDULES687
Daily687
Normal Maintenance Based On Actual Operating Hours687
IN CASE OF FIRE688
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM690
POSSIBLE CAUSES690
SUGGESTED CORRECTIVE ACTION690
TROUBLE: Test Module Light Will Not Illuminate690
POSSIBLE CAUSES690
SUGGESTED CORRECTIVE ACTION690
TROUBLE: Test Module Light Will Not Go Out690
POSSIBLE CAUSES690
SUGGESTED CORRECTIVE ACTION690
TROUBLE: Detonated Squib690
POSSIBLE CAUSES690
SUGGESTED CORRECTIVE ACTION690
SECTION M8 – SPECIAL TOOLS692
SECTION M20 – PAYLOAD METER II – ON BOARD WEIGHING SYSTEM – INDEX698
GENERAL INFORMATION700
Haul Cycles700
LIGHTS, SWITCHES AND COMPONENTS701
TIPS FOR OPERATION702
EXTERNAL DISPLAY LIGHTS702
THEORY OF OPERATION703
Basic Description703
Inclinometer703
Linkage Factor703
Gain Factor704
Brake Lock704
Sources of Error704
Typical Data From Service Check Mode704
Example Calculation of Payload705
Viewing Payload Calculation Inputs705
Checking the Gain706
Adjusting the Gain706
TYPES OF DATA STORED707
Cycle Data707
Engine ON/OFF Data708
Fault Codes and Warning Data708
Engine Operation709
Total Payload and Total Number of Cycles709
Other Data709
OPERATOR FUNCTIONS710
Using the Operator Load Counter710
Viewing the Operator Load Counter710
Clearing the Operator Load Counter710
Dimming the Lights on the Display710
INITIAL SETUP OF PAYLOAD METER711
Switch Settings711
Checking the Operator Check Mode712
Checking the Service Check Mode712
Checking the Gt setting:713
Checking the Inclinometer Settings713
Calibrating a Truck713
DISPLAYS AT START-UP714
Normal Operation714
SETUP AND MAINTENANCE715
Setting The Speed Limit715
Setting the Option Code715
Setting The Machine ID Code716
Setting The Operator ID Code716
Setting The Time and Date716
DOWNLOAD OF INFORMATION717
DISPLAY OF FAULT CODES717
Monitoring Input Signals721
Service Check Mode721
UP FACTOR – PAYLOAD CALCULATION GAIN722
PL MODE -LOAD CALCULATION TIMING722
FINAL GEAR RATIO SELECTION723
BATTERY REPLACEMENT PROCEDURE724
Replacing the Battery724
After Replacing the Battery725
SUSPENSION PRESSURE SENSOR725
Removal725
Installation726
INCLINOMETER726
Removal726
Installation726
Adjustment726
PAYLOAD METER BACK PANEL727
CONNECTIONS728
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE729
PAYLOAD CIRCUIT NUMBERS730
TROUBLESHOOTING731
COMMON PROBLEMS731
Suspension Charging731
Symptom Table732
Missing Body-Up Signal732
Missing Speed Signal733
F-18: Alternator R-Terminal, Oil Pressure Signals733
Shorted 18v Sensor Power Supply (930E)733
FAULT TREE DIAGNOSIS734
Payload Lights Won’t Illuminate734
Red, Amber or Green Payload Light Does Not Illuminate735
Cannot Download – PC Communications736
PC Communications Configuration737
FCAL: Payload Meter Won’t Calibrate738
F-20: Sensor Power Fault739
F-21, F-25: Left Front Pressure Sensor741
F-22, F-26: Right Front Pressure Sensor741
F-23, F-27: Left Rear Pressure Sensor741
F-24, F-28: Right Rear Pressure Sensor741
F-31, F-32: Inclinometer743
Body Up Input745
Brake Lock Input746
Speed Signal747
Adjusting the Speed Sensor747
CONNECTORS AND PRESSURE SENSORS749
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM752
Menu Functions755
Using Scope755
Log File Information755
Connections to Payload Meter II™756
USING SCOPE757
Monitoring Inputs Using Scope757
Monitoring Suspension Charging Using Scope757
Pressure Sensor Dummy Loads760
GAIN ADJUSTMENT WORKSHEET761
SECTION N762
CAB COMPONENTS762
INDEX762
SECTION N – CAB COMPONENTS – INDEX762
SECTION N2 – TRUCK CAB – INDEX764
TRUCK CAB766
Description766
Preparation767
Removal – Cab767
Installation – Cab769
CAB DOOR769
Removal769
Installation769
Door Adjustment770
Door Jamb Bolt Adjustment770
Door Handle Plunger Adjustment771
Door Glass Replacement772
Door Window Regulator Replacement776
Door Handle or Latch Assembly Replacement776
Door and Door Hinge Seal Replacement777
Door Opening Seal Removal777
Installation777
GLASS REPLACEMENT778
Adhesive Bonded Windows778
Replacement Procedure778
Windshield And Rear Glass779
Removal779
Installation780
SECTION N3 – CAB COMPONENTS – INDEX782
CAB COMPONENTS784
WINDSHIELD WIPERS784
Wiper Motor Replacement784
Removal784
Installation784
Wiper Arm Replacement784
Removal784
Installation785
Wiper Linkage Replacement785
Removal785
Installation785
WINDSHIELD WASHER786
Operation786
Service786
OPERATOR SEAT787
Adjustment787
Removal787
Installation787
SECTION N4 – OPERATING COMFORT – INDEX788
OPERATOR COMFORT790
HEATER/AIR CONDITIONER790
Operation790
HEATER COMPONENTS791
Circuit Breakers791
Heater Control Components791
Heater Coil791
Fan Motor And Speed Control792
Actuators792
Filter Service792
AIR CONDITIONING SYSTEM794
Environmental Impact794
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES795
PRINCIPLES OF REFRIGERATION795
Air Conditioning795
Refrigeration – The Act Of Cooling796
The Refrigeration Cycle796
AIR CONDITIONER SYSTEM COMPONENTS797
Compressor (Refrigerant Pump)797
Service Valves797
Condenser797
Receiver-Drier797
Expansion Block Valve798
Accumulator798
Evaporator798
ELECTRICAL CIRCUIT799
Thermostat799
Compressor Clutch799
Trinary™ Switch800
SYSTEM SERVICING801
SERVICE TOOLS AND EQUIPMENT802
Recovery/Recycle Station802
Leak Detector802
Service Valves803
Vacuum Pump803
Manifold Gauge Set804
Installing Manifold Gauge Set805
Purging Air From Service Hoses805
SYSTEM PERFORMANCE TEST806
SYSTEM OIL807
Handling and Reusing PAG Oil807
Oil Quantity807
Checking System Oil807
REFRIGERANT808
Recycled Refrigerant808
Reclaimed Refrigerant808
Refrigerant Quantity808
R-134a Refrigerant Containers808
SYSTEM LEAK TESTING809
Electronic Leak Detector809
Tracer Dyes809
Soap and Water809
RECOVERING AND RECYCLING THE REFRIGERANT810
Performing the Recovery Cycle810
Performing the Recycling Procedure810
Evacuating and Charging the A/C System810
SYSTEM REPAIR811
System Flushing811
COMPONENT REPLACEMENT811
Hoses and Fittings811
Lines811
Expansion Valve812
Receiver-Drier812
Thermostat812
Compressor812
Accumulator812
Clutch813
Servicing the Compressor Clutch813
Pulley Removal815
Clutch Coil Check816
Pulley Installation816
Clutch Assembly Installation816
EVACUATING THE SYSTEM818
CHARGING THE A/C SYSTEM820
TROUBLESHOOTING821
Preliminary Checks821
Diagnosis Of Gauge Readings And System Performance821
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS822
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM828
SECTION N5 – OPERATOR CAB CONTROLS – INDEX830
OPERATOR CAB CONTROLS832
STEERING COLUMN832
Removal832
Installation832
STEERING WHEEL AND CONTROLS834
DYNAMIC RETARDING834
RETARDER CONTROL LEVER835
DYNAMIC RETARDER/SERVICE BRAKE PEDAL835
ACCELERATOR (THROTTLE) PEDAL835
Starting on a Grade With a Loaded Truck835
GRADE/SPEED RETARD CHART836
HEATER / AIR CONDITIONER VENTS837
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS837
DEFROSTER VENT CONTROL SWITCH837
HEAT VENT CONTROL SWITCH837
FAN CONTROL KNOB837
AIR CONDITIONER CONTROL KNOB837
OUTSIDE/INSIDE AIR CONTROL SWITCH837
SELECTION CONTROL SWITCH837
HEATER/AIR CONDITIONER VENTS837
INSTRUMENT PANEL838
OVERHEAD PANEL AND DISPLAYS838
F-N-R SELECTOR SWITCH839
HOIST CONTROL LEVER840
OVERRIDE /FAULT RESET SWITCH841
10, FIGURE 5-5 – BLANK841
RETARD SPEED CONTROL (RSC) “OFF/ON” SWITCH841
RETARD SPEED CONTROL (RSC) ADJUST DIAL841
TCI DOWNLOAD PORT842
PASSENGER SEAT842
INSTRUMENT PANEL AND INDICATOR LIGHTS844
CONTROL SYMBOLS844
INSTRUMENT PANEL (Figure 5-6)844
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)846
KEY SWITCH846
Starting846
Cold Weather Starting846
Normal Engine Shutdown846
Operation847
PARKING BRAKE CONTROL848
AC DRIVE SYSTEM TEMPERATURE GAUGE850
STATUS / WARNING INDICATOR LIGHT SYMBOLS853
SECTION P860
LUBRICATION AND SERVICE860
INDEX860
SECTION P – LUBRICATION AND SERVICE – INDEX860
SECTION P2 – LUBRICATION AND SERVICE – INDEX862
LUBRICATION AND SERVICE864
930E SERVICE CAPACITIES864
HYDRAULIC TANK SERVICE864
Adding Oil864
WHEEL MOTOR SERVICE864
COOLANT LEVEL CHECK865
RADIATOR FILLING PROCEDURE865
LUBRICATION CHART866
10 HOUR (DAILY) INSPECTION867
50 HOUR LUBRICATION AND MAINTENANCE CHECKS870
100 HOUR LUBRICATION AND MAINTENANCE CHECKS871
250 HOUR LUBRICATION AND MAINTENANCE CHECKS872
500 HOUR LUBRICATION AND MAINTENANCE CHECKS875
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS876
5000 HOUR MAINTENANCE CHECKS877
SECTION P3 – LINCOLN AUTOMATIC LUBRICATION SYSTEM – INDEX878
LINCOLN AUTOMATIC LUBRICATION SYSTEM880
System Components880
System Operation882
GENERAL INSTRUCTIONS883
Lubricant Required for System883
System Priming883
SYSTEM CHECKOUT883
24 VDC SOLID STATE TIMER CHECK884
24 VDC Solid State Timer Adjustment884
INJECTORS (SL-1 Series “H”)885
Injector Specifications885
Injector Adjustment885
INJECTOR OPERATION886
PUMP CYCLE TIMER (FLASHER TIMER)887
Pump Cycle Timer (Flasher Timer) Installation887
Pump Cycle Timer (Flasher Timer) Adjustment:887
Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (NC)887
PRESSURE REDUCER ADJUSTMENT889
TROUBLESHOOTING CHART890
Preventative Maintenance Procedures893
Daily Lubrication System Inspection893
250 Hour Inspection893
SECTION Q ALPHABETICAL INDEX894
SECTION R898
HH337 – HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC900
HH348 – HYDRAULIC BRAKE SYSTEM SCHEMATIC901
EG9625 – ELECTRICAL WIRING SCHEMATIC902

IMAGES PREVIEW OF THE MANUAL:

S.M 14/12/24